Dantherm DanX XWPRS Series User manual

DanX Pool XWPRS
User Manual
Rev. 2.3 - 066422
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
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
3.1.1 Unit construction DanX –XWPRS................................................................................................... 6
3.2 Installation of modules............................................................................................................................. 7
3.2.1 Modules side by side ....................................................................................................................... 8
3.2.2 Modules above each other .............................................................................................................. 9
3.2.3 Half height hanging filter modules ................................................................................................... 9
3.2.4 Duct mounting................................................................................................................................ 10
3.2.5 Outdoor unit ................................................................................................................................... 10
3.3 Installation and connection of components........................................................................................... 11
3.3.1 Cooling circuit XWPRS 16/32........................................................................................................ 11
3.3.2 Drop bridge .................................................................................................................................... 12
3.3.3 Condensed water outlet................................................................................................................. 13
3.3.4 Damper motors .............................................................................................................................. 13
3.3.5 Filter gauges .................................................................................................................................. 13
3.3.6 Supply air temperature duct sensor............................................................................................... 14
3.3.7 Return air humidity / temperature duct sensor .............................................................................. 14
3.3.8 Room air humidity / temperature sensor........................................................................................ 14
3.3.9 Separate outdoor sensor ............................................................................................................... 14
3.3.10 Frequency inverter for AC fan motors.......................................................................................... 15
3.3.11 Water cooled condenser.............................................................................................................. 16
3.3.12 LPHW coil .................................................................................................................................... 17
3.3.13 Frost thermostat for LPHW coil.................................................................................................... 17
4. Commissioning.......................................................................................................................................... 18
4.1 Introduction............................................................................................................................................ 18
4.1.1 Unit function DanX –XWPRS........................................................................................................ 18
4.2 Fans....................................................................................................................................................... 19
4.2.1 Pressure transducer....................................................................................................................... 19
4.2.2 Air volume check............................................................................................................................ 20
4.2.3 Frequency inverter setup............................................................................................................... 21
4.3 XWPRS section..................................................................................................................................... 22
4.3.1 Cooling circuit ................................................................................................................................ 22

0. TABLE OF CONTENTS
2
4.3.2 Dampers ........................................................................................................................................ 23
4.4 Frost thermostat .................................................................................................................................... 23
4.5 Filter pressure transmitter ..................................................................................................................... 23
5. Maintenance............................................................................................................................................... 24
5.1 Introduction............................................................................................................................................ 24
5.2 Maintenance plan.................................................................................................................................. 24
5.3 Cabinet.................................................................................................................................................. 24
5.4 Fans....................................................................................................................................................... 25
5.5 Filter....................................................................................................................................................... 25
5.6 Heating coil............................................................................................................................................ 26
5.7 Cross flow heat exchanger.................................................................................................................... 26
5.8 Dampers................................................................................................................................................ 26
5.9 Cooling circuit........................................................................................................................................ 26
5.10 Drop catcher........................................................................................................................................ 27
6. Faultfinding ................................................................................................................................................ 28
6.1 Introduction............................................................................................................................................ 28
6.2 Fault finding........................................................................................................................................... 28
7. Disposal...................................................................................................................................................... 30
7.1 Disposal of the unit................................................................................................................................ 30
8. Appendix .................................................................................................................................................... 31
8.1 Parameter settings FC 101 ................................................................................................................... 31

1. GENERAL
3
Ge neral
1.1 Introduction
The DanX type XWPRS equipment is designed 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 be 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 level, stable and vibration-free.
•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
must 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 wall should be the width of
the unit. It is also recommended to have a minimum clearance of 600 mm between the wall
and the rear of the unit for service and installation purposes.
Model
W min [mm]
Model
W min [mm]
DanX 2/4
900
DanX 9/18
1800
DanX 3/6
900
DanX 12/24
2200
DanX 5/10
1400
DanX16/32
2200
DanX 7/14
1900

2. TRANSPORTATION
4
2.T ransport 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 2500 kg).
•Unload the modules with a forklift or crane (see instructions below).
•Do not tilt or lay down modules with integrated refrigeration system (compressor).
•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 walk under a module when it is lifted with a crane.
There is always a risk that the crane or helping material may break and cause serious injuries
or death.
Please 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 in 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
There is one basic model of DanX unit for swimming pool ventilation. Your DanX unit may
differ a little from this. If you are in doubt how to assemble the modules, please ask you
supplier for an exact drawing of the unit.
The units shown in the drawings in this manual are all left hand units, with the outdoor air
coming from the right hand side. If you have a right hand unit all components of the unit are
the other ways around.
Assembly of the DanX modules should only be 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.
3.1.1 Unit construction DanX –XWPRS
The DanX –XWPRS consist of a cross flow heat exchanger in combination with a compressor
driven heat pump in the same module and a separate mixing box The cooling circuit is
mounted in the XWPRS module, filled with refrigerant and do not need any extra installation.
From left to right the unit consists of the following components/modules:
1) Heating coil with supply air fan below.
2) Return air fan and return air filter above.
3) Cross flow heat exchanger with heat pump.
4) Mixing box and outdoor filter above.

3. INSTALLATION
7
3.2 Installation of modules
Before placing the single modules in the right order, accordingly to chapter 3.1 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 modules 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 gaskets (2) at the end of each module that they are not damaged or
loose. This is important, as it is impossible to replace the gaskets 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 on the base frame (see drawing) and place the modules as close as
possible together where they should be installed. When the feet are mounted it is only
possible to move the modules a few millimetres, otherwise the feet can bend or break.
If you have to move the modules more, then use a fork lift or pallet lift.
1
2

3. INSTALLATION
8
3.2.1 Modules side by side
After placing all bottom modules in the right order on the floor, the modules must be
assembled. If the unit includes halve height modules, install the bottom modules before the
top modules.
Follow these steps for mounting the modules:
•Adjust the height of the modules with 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 neighbour modules by pushing assembly rails (2) 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 into smaller pieces, which are then mounted in the same
way.
•To finish the installation all modules must be connected with the green/yellow earth
connection (3) at the top of the modules.
1
2
3

3. INSTALLATION
9
3.2.2 Modules above each other
After the installation of the bottom modules (se chapter 3.2.1) the halve height top modules
can be placed above the bottom modules in the following way.
•Lift the module with a fork lift and push the module from the wooden pallet onto the
bottom module.
•Use a strap to get the modules as close together as possible. Straps should only be
mounted at the bottom or/and top of the modules
•Use the assembly rails as described in chapter 3.2.1, not only vertical but also horizontal
to connect the upper module with the module below.
3.2.3 Half height hanging filter modules
Half height hanging filter modules are mounted on a set of support brackets (to be found in a
box inside the module).
Follow these steps for mounting the modules:
•Screw the two brackets into the end frame of the DanX unit, by using the bolts delivered
with the brackets.
•Lift the filter module onto the brackets
•Fasten the filter module with the assembly rails to the top and side of the DanX. The
assembly rails can only be used on three sides and not beneath the module.
•Use the self-cutting screws to fasten the filter module to the support brackets.
Important:
If the module is longer than 880 mm or contains other functions than a filter, the module must
be supported at the free end of the module, to avoid that the module sinks.
This supporting is not included in the delivery.

3. INSTALLATION
10
3.2.4 Duct mounting
The ducts connected to the AHU must 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 connection must be mounted between unit and duct work.
3.2.5 Outdoor unit
Installation of outdoor and indoor units are done in the same way, however, outdoor units often
come completely assembled on one base frame, ready to be lifted onto the roof in one piece.
Outdoor units must have a roof cover, which is delivered separately together with the unit.
Depending on the length of the unit, the roof cover consists of two gable ends (1) and one or
more middle parts.
•Assemble the roof panels with the rails and bolts (2) delivered with the roof as shown in
the drawing.
•Finish the installation by securing the assembled roof with self-cutting screws (3) to the
upper frame of the units as shown in the drawing.
1
1
3
3
2
2

3. INSTALLATION
11
3.3 Installation and connection of components
All components and duct work of the air handling unit must be installed correctly before starting
up and commissioning the DanX unit.
Installation and connection work should only be 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.
3.3.1 Cooling circuit XWPRS 16/32
Because of the weight of the cooling section, the XWPRS 16/32 is delivered in two parts. This
means that the cooling circuit first has to be connected before the compressor can be started
up. To connect the cooling circuit the following has to be done:
•Take the three copper pipes for the cooling circuit (A/B/C) out of the box which is inside
the XWPRS module.
•Check that the pipes are totally clean before installation.
•Install the three pipes at each end of the cooling circuit after the shoot off valves (see
drawing)
•Open for all six shoot off valves and check that the connections a tied with no refrigerant
leakage.

3. INSTALLATION
12
3.3.2 Drop bridge
To avoid condensate leaving the unit through the module joint, a bridge must be mounted
between the two drip trays of the modules. This bridge is delivered separately and should be
mounted when the modules are in place.
•Place a strip of sealing on the backside of the bridge (Detail C)
•Turn over the bridge and place it between the two drip trays with the sealed side facing
the drop catcher.
•If the sealing should not be enough to keep the bridge in place, it is possible to fasten
the two ends of the bridge to the module frame with two rived nuts (Detail B).
It is important that the drop bridge is installed and sealed correctly, to avoid uncontrollable
discharge of condensed water and water damage of the building!

3. INSTALLATION
13
3.3.3 Condensed water outlet
Drainage from the condensate tray is taking place through a connection in front of the
inspection side through the cover panel. On a XWPRSS unit will be three condense outlets,
two on the exhaust side (negative pressure) and on the supply side (positive pressure). On
XKS and XK 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.
Positive pressure : H1 = 50 mm H2 = ∆p + 50 mm
Negative pressure : H1 = ∆p + 50 mm H2 = ∆p / 2 + 50 mm
∆p = pressure in mm WS (100 Pa = 10 mm WS)
3.3.4 Damper motors
All damper motors, except in the mixing module, are installed, prewired and connected to the
terminal strip of the XWPRS or WP. The prewired damper motors in the mixing module must
be connected to the terminal strip of the XKP or WP module after the installation of the unit.
You will find the 3 pole wiring cable inside the mixing module. For further information see the
electrical diagram of the unit.
3.3.5 Filter gauges
The filter gauges for outside and return air are mounted at the front of the XWPRS or WP
module and prewired to the terminal strip.
After assembling the unit the pressure tubes have to be connected to the probes in the filter
section. You find the pressure tubes, which are marked –and +, inside the main section. Run
the pressure tubes inside the cable channel to the filter section and connect the + tube to the
probe behind the filter and the –tube to the probe before the filter.

3. INSTALLATION
14
3.3.6 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.
3.3.7 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.
3.3.8 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.
3.3.9 Separate outdoor sensor
If there is ordered a separate outdoor temperature sensor, you will find the sensor separately
in the electrical panel without cabling. Install the sensor outside the building where there is no
direct sunlight. Disconnect the standard outdoor sensor which is installed inside the DanX unit
(see electrical diagram) and connect the new outdoor sensor to the two terminals.

3. INSTALLATION
15
3.3.10 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.

3. INSTALLATION
16
3.3.11 Water cooled condenser
The heat pump in a DanX XWPRS swimming pool unit may be fitted with a water-cooled
condenser for transfer of surplus heat, which is not used for heating the return/supply air, to
the pool or sanitary water. The drawing below shows Dantherm’s suggestion on how to
connect the water cooled condenser to the swimming pools water supply.
1. Main pump for pool water
2. Temperature sensor pool water (separate water temperature control)
3. Manual shut down valve
4. Pump for water cooled condenser (control signal from DanX control panel)
5. Water consumption gauge
6. Regulation valve
7. Temperature sensor (separate water temperature control with on/off signal to DanX
control panel)
8. 3 way valve (separate water temperature control)
10. Temperature gauge
13. Air release valve
14. Non return valve
15. Separate heat exchanger for pre heating sanitary water
NB!
Piping material must be suitable for chlorine water.
Please be aware of the specified max. water volume (see table below), as a to high water
velocity can destroy the water cooled condenser and cooling circuit of the DanX unit.
XWPRSS
2/4
3/6
5/10
7/14
9/18
12/24
16/32
Max water L/h
800
1250
1900
2750
2750
5300
5300

3. INSTALLATION
17
3.3.12 LPHW coil
The supply is always connect to the bottom of 1 and 2 row LPHW coils, as this makes it easy
to bleed the coil for air.
If the coil is larger than 2 rows, the water and air flow must be counter flow to obtain the
calculated heat capacity.
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.
3.3.13 Frost thermostat for LPHW coil
The frost thermostat is normally placed in the compartment above the LPHW heating coil, with
the capillary tube mounted on the heating coil. The thermostat is prewired and the wire only
has to be connected to the main terminal strip of the unit (see wiring diagram).

4. COMMISSIONING
18
4.Co mmission ing
4.1 Introduction
When servicing on air handling units always turn off the electricity on the main switch and the
repair switch (complete shutdown) 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
stop. 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 be 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.
4.1.1 Unit function DanX –XWPRS
The DanX –XWPRS consist of a cross flow heat exchanger in combination with a compressor
driven heat pump for heating, cooling and dehumidification in the same module.
The DanX XWPRS is using a minimum of outdoor air which is required for hygienic reasons
in the pool hall. To keep pressure drop low and have a high dehumidification capacity in the
heat pump, only a part of the wet swimming pool air is run through the heat exchanger and
evaporator.
Part of the exhaust air is leaving the unit and part of the exhaust air is re-circulated to join the
outdoor air. These two airstreams are then preheated in the cross flow heat exchanger and
afterwards heated in the heat pump condenser. If the supply air temperature is too low the
re-heater is activated. In this operation mode the dehumidification is obtained with the dry
outdoor air and heat pump. If the dehumidification capacity is not sufficient the amount of dry
outdoor air automatically increases.
For further explanations about the controls of this unit, please refer to the manual of the control
panel.