Dantherm HCV 4 User manual

HCV 4 / HCV 5
Installation manual
Rev. 1.1
EN•DA•DE•FR

2
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

1
070719 •Version 1.1 • 05.10.2012
EN
Introduction
Overview
Introduction
This is the installation and service manual for the HCV 4 and HCV 5v12 domestic venti-
lation units from Dantherm Air Handling.
The table of contents below lists the sections in this manual.
Serial number
This guide covers units with serial numbers higher than: 1201091250905
Warning
The duct system must not be installed until the unit is ready for use. The power must
not be connected until the duct system has been installed.
The ventilation unit should not be used to dry newly built houses, during construction
or immediately after construction.
The unit should only be installed at ambient temperatures of 10° or higher.
The ducts must be covered, and the unit must not be connected until the house is ready
for occupation, which means that the house is clean and dry. This is to prevent building
dust and condensation from settling in the duct system and to prevent hygiene prob-
lems in the ventilation unit at a later date.
If the above is not complied with, the warranty on the unit will lapse and any type of
service will be carried out at the customer's expense.
Content
The manual covers the following sections:
Introduction................................................................................................................1
Overview..............................................................................................................1
General information .............................................................................................2
Product description..............................................................................................3
Assembly and installation ...........................................................................................5
Assembly .............................................................................................................5
Adjustment..........................................................................................................9
Set points and control strategies ........................................................................13
Service......................................................................................................................14
Preventive maintenance......................................................................................14
Spare parts list HCV 4 ........................................................................................17
Spare parts list, HCV 5v12..................................................................................19
Troubleshooting guide.......................................................................................21
Service agreement..............................................................................................26
Technical data ...................................................................................................27
Dimensions, HCV 4 ............................................................................................29
Dimensions, HCV 5v12.......................................................................................30
Electrical diagram ..............................................................................................31
Index .................................................................................................................32

2
General information
Introduction
This section provides general information about the installation manual and the unit.
Manual product
number
The product number of this installation and service manual is 070719.
Target group
The target group for this manual is the engineers installing and adjusting the unit, and
carrying out preventive maintenance and replacing defective parts.
Copyright
Copying this manual or parts thereof is not permitted without prior written permission
from Dantherm Air Handling A/S.
Reservations
Dantherm Air Handling A/S reserves the right at any time to make changes or improve-
ments to the product and installation and service manual without prior notice or obliga-
tion.
EU Declaration of
Conformity
Dantherm Air Handling A/S, Marienlystvej 65, DK-7800 Skive declares at its own liability
that the following product:
352425 HCV 4
352422 HCV 5v12
covered by this declaration, complies with the following directives:
2006/42/EC Machine Safety
2006/95/EC LVC Directive (low voltage)
2004/108/EC EMC Directive
2002/95/EC RoHS Directive
2002/96/EC WEEE-direktiv
- and is manufactured in compliance with the following harmonised standards:
EN 12100 Machine Safety
EN 60 335-1 Low Voltage
EN 60 335-2 Low Voltage
EN 61 000-6-1:2007 EMC Immunity
EN 61 000-6-3:2007 EMC Emission
EN 55 014-1:2007 EMC Emission
EN 55 014-2:1997 EMC Immunity
EN 55 022:2006 Radio Interference
Skive, 28.05.2009
Disposal
The unit is designed to last for many years. When the times comes for the unit to be
disposed of, such disposal must be carried out in compliance with national legislation
and procedures to protect the environment.

3
070719 •Version 1.1 • 05.10.2012
EN
Product description
Introduction
This section provides a description of the unit.
The use of the HCV
The HCV is used for domestic ventilation. The unit supplies fresh, heated outdoor air
through the unit to the house. Polluted and warm extract air is used to heat up the out-
door air by means of heat recovery.
Illustration, internal
The illustration shows the different parts of the unit seen from within:
Parts
The table lists the main parts in the unit:
No.
Part
No.
Part
1
Heat exchanger
8
Air supply filter (G4/F7)
G4 filter is standard, F7 pollen filter is an op-
tional extra
2
Electrical connections (located at
the bottom of the HCV 5)
9
Temperature sensor, T4
3
Temperature sensor, T2
10
Controls
4
Temperature sensor, T3
11
Reset button for filter timer
5
Humidity sensor
12
Supply air fan module
6
Temperature sensor, T1
13
Extract air fan module
7
Exhaust filter (G4)
14
Drain/drip tray
15
Bypass (only HCV 5)
Continued overleaf

4
Product description, continued
Air flow
The air flow through an HCV is described and illustrated below:
No.
Description
T1
Outside air
Outside air entering the heat exchanger ready to be
heated by the extract air from the house
T2
Supply air
The supply air is heated by means of heat recovery from
the extract air
T3
Extract air
"Polluted" and warm extract air is used to heat up the
outside air by means of heat recovery in the heat ex-
changer
T4
Exhaust air
The heat of the extract air is used to heat the cold out-
side air. The exhaust air is led out of the house.
T2 T3 T4 T1

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070719 •Version 1.1 • 05.10.2012
EN
Assembly and installation
Assembly
Introduction
This section describes assembly and installation of the HCV unit.
Important
Only trained and certified technicians are permitted to install the unit!
Warranty
The warranty will lapse if the assembly instructions below are disregarded.
Content of the box
Follow this procedure to check the content of the box:
Step
Action
1
Unpack the unit carefully.
2
Check the content before assembling the unit.
HCV unit
Power cable EU/DK
Mounting rail with rubber straps
Two spacers
2 m discharge pipe
User guide, installation and service
manual
Electrical protection cap + screws
Ducts
The ducts connected to the unit must have at least the same diameter as the unit's duct
connection or larger. Dimensions can be seen in the technical data section
Dimensions of ducts and sound absorbers must be in conformity with national stand-
ards and guidelines in the current building legislation. Contact your Dantherm dealer
for further advice.
Noise and vibrations from the unit to the ducts must be minimized. This can be
achieved by installing sound absorbers on both the supply and exhaust air sides.
The ducts must be covered and the unit must not be connected until the house is
ready for occupation, which means clean and dry. This is to prevent building dust
and condensation from settling in the duct system and to prevent hygiene prob-
lems in the ventilation unit at a later date.
Continued overleaf

6
Assembly, continued
Assembling the unit
Follow the procedure below to assemble the unit:
Step
Action
1
Install the mounting rail horizontally
on the wall with four screws which are
appropriate to the material and thick-
ness of the wall and mount the rubber
strap on the rail as shown.
The screws must have a breaking
strength of at least 365 N.
NOTE: Please note that Dantherm Air
Handling is able to provide spe-
cial fixtures to reduce the depth
of the unit if the HCV 4 needs to
be built into a cabinet with a
door.
2
Mount the two spacers on the back of
the unit as shown.
3
Lift the unit onto the mounting rail.
Due to the weight of the unit, two
people are required to lift it into place.
4
Connect the discharge pipe to the pipe
connection. Use lubrication if re-
quired.
Continued overleaf

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070719 •Version 1.1 • 05.10.2012
EN
Assembly, continued
Assembling the unit,
continued
Step
Action
5
We recommend using a Dantherm water trap (optional extra). Alternatively,
you can produce a water trap with the dimensions shown. Fill the trap with
water during installation to prevent air entering through the pipe during ad-
justment and operation of the system.
6
Lead the pipe to the drain –the whole discharge pipe must be kept frost-free
to ensure that the water can run freely. The pipe must have a minimum gradi-
ent of 1% from unit to drain.
7
Nipple connections can be used on
this unit. Dantherm Air Handling rec-
ommends connections to the duct
system using sound absorbers with
nipples (T2/T3) where physically pos-
sible (rectangular, if required), and
remaining connections using NPU nip-
ple and insulated flexible ducts. Flexi-
ble ducts must be fully stretched and
without kinks to avoid unnecessary
loss of pressure.
Connection
Outside air T1
Supply air T2
Extract air T3
Exhaust air T4
8
The whole duct system should be insulated with a minimum of 100 mm insu-
lation. Place the ducts e.g. under a minimum of 100 mm ceiling insulation. If
insulation is used around the pipe, we recommend two layers of insulation
with foil on the outside. The insulation must sit tightly around the ducts.
9
The two layers should have staggered joints, which should be taped until air-
tight.
10
Insulate all flex ducts with 100 mm
The insulation of flex ducts in the heated part of the house may, however, be
reduced to 50 mm by the unit due to lack of space.
11
Choose the correct power supply cable to comply with in-country regulations
and connect the cable's IEC plug to the unit. Then connect the plug to 230 V
AC.
Continued overleaf
T4
T1
T2
T3

8
Assembly, continued
Step
Action
12
Assemble the plug's protection with
the screws included.
13
Adjust the unit by following the Adjustment instructions
Drifting snow, driv-
ing rain and conden-
sation
Air inlets and outlets T1 and T4 must be installed across the ceiling with a gradient
away from the ventilation system. The purpose is to prevent any drifting snow, driving
rain or condensation running down into and damaging the ventilation system, installa-
tion and house.
The warranty does not cover damage to the unit, building parts or insulation caused by
accumulated snow/water in the ducts.
Optional extras
To install optional extras from Dantherm Air Handling A/S, follow the instructions sup-
plied with the part.

9
070719 •Version 1.1 • 05.10.2012
EN
Adjustment
Introduction
This section guides you through the initial adjustment of the HCV unit
Important
Only trained and certified technicians are permitted to install the unit!
Legislation
Initial adjustment of air flow rates must always be carried out in accordance with na-
tional legislation. Only the nominal air flow requires initial adjustment. The nominal air
flow is Fan Step 3 in Manual Operation Mode on the control panel. More at Description
of the Control Panel' section in the user guide.
When
The unit must be adjusted in the following situations:
Before the unit is used for the first time
If the size of the house changes
If the house is renovated and the duct system is affected by the renovation
If the filter type is changed e.g. during the pollen season
Before you start
All air valves in the duct system must be set according to the manufacturer's/supplier's
recommendations before an initial adjustment of the HCV is commenced.
Ensure that you have the following at hand before you start the installation:
Pressure manometer with approx. 5 mm pipes matching the pressure connections
on the unit, which are 6 mm
Initial adjustment of
air flow
When the initial adjustment is carried out, it is important to ensure that the air flows are
the same!
Important:
The supply air flow (T2) must under no circumstances be higher than the extract air
flow (T3). If it is, it may mean that humid air is pressed into the building structure,
which can have a destructive effect on the building if the vapour shield is not 100% air-
tight.
Procedure
Follow this procedure to adjust the unit:
Step
Action
1
Open the top door
2
Remove the two screws on the top of the bottom
door and remove the door by tilting it and lifting it
up.
3
Check that the foam insulation plates in front of the
filters are correctly mounted with the soft side fac-
ing the filter. Push the plates firmly against the filter
to prevent any unwanted air being drawn in that
way.
Continued overleaf

10
Adjustment, continued
Procedure, continued
Step
Action
2
Turn off the power supply to the unit and wait for 10 seconds. Then turn the
power back on.
3
Activate Installation Mode by pressing Manual + Auto for 6 seconds. Af-
ter this, Fan 3 lights up constantly.
NOTE: Installation Mode is active for one hour. In Installation Mode, frost protec-
tion and filter compensation are bypassed to prevent disruption during adjust-
ment on Fan Step 3.
Installation Mode is switched off with the same action.
4
How to set the air flow.
Set a desired air flow in accordance with national regulations and requirements,
based on the size and air usage in the house:
Step
Action
1
Write down the supply and exhaust air flow rates in the graph.
2
Read and write down the corresponding pressure loss to be achieved
through the heat exchanger.
3
Adjust the unit.
4
Write down the settings from the control panel potentiometers in the
table later in this procedure.
Continued overleaf
Pressure loss through the
heat exchanger
The plotted values and handwritten data are for illustrative purposes only
216
230
48
58
50
59
P1 - P2 Supply air P3 - P4 Extract air

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070719 •Version 1.1 • 05.10.2012
EN
Adjustment, continued
Procedure, continued
Step
Action
5
Install the manometer on pressure pipe P1
and P2 and measure the supply air pres-
sure loss through the heat exchanger.
P2
P1
6
Adjust the main air flow on the supply air
side by adjusting the potentiometer for
the supply air fan until the required pres-
sure difference has been achieved. The
potentiometer can be found on the con-
trol panel.
After adjusting the potentiometers, wait
approx. 2 minutes until the unit is stable
again.
Strong wind against the building may
affect the adjustment of the unit.
7
Connect the pressure manometer to the
pressure pipes P3 and P4 and measure the
pressure loss through the heat exchanger.
P3
P4
Continued overleaf

12
Adjustment, continued
Procedure, continued
Step
Action
8
Adjust the main air flow on the exhaust air side by
adjusting the potentiometer for the exhaust fan un-
til the required pressure difference has been
achieved. The potentiometer can be found on the
control panel.
After adjusting the potentiometers, wait approx. 2
minutes until the unit is stable again.
Strong wind against the building may
affect the adjustment of the unit.
9
Check the pressure difference on the supply air side as this may have changed
after adjustment of the exhaust air.
Adjust if necessary.
10
Adjust the valves in all rooms until the required air flow for each room has
been achieved.
11
Check the main air flows according to the instructions earlier in this procedure
as major valve adjustment may greatly affect the main air flow.
12
Write down the final settings for potentiometers, air pressure and air flow in
the table on the unit:
After initial adjust-
ment
Deactivate Installation Mode by pressing Manual + Auto for 6 seconds.
The various operating modes are described in detail in the user guide.
216
23058
4860
70
[m3/h]
[m3/h]
___
___
___
___
___

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070719 •Version 1.1 • 05.10.2012
EN
Set points and control strategies
Introduction
This section describes the different factory settings for the unit and the adjustment op-
tions on the control panel and remote control.
Factory setting
Current factory settings:
Set point
Factory setting
Settings range
HCP 4
control panel
HRC 2
remote control
Fan Step 0
OFF
-
-
Fan Step 1
Gear 14
Gear 1 - 41
Gear 1 - 71
Fan Step 2
Gear 39
Gear 21 - 66
Gear 36 - 81
Fan Step 3
Gear 64
Gear 46 - 91
Gear 46 - 91
Fan Step 4 (maximum speed)
Gear 100
Gear 100
From Fan Step
3 to Gear 100
'OFFSET'
(gear between Fan Steps 1-2-3)
25 gears
-
10 - 30 gears
Automatic On-Demand Mode (RH%)
45%
45%
35-65%
Filter period
180 days
180 days
90-360 days
Frost protection of the exchanger
Frost protection of afterheat
T4 ≤ + 2°C
T2 ≥ + 5°C
-
-
-
-
Frost protection
How the frost protection works:
1) Frost protection of exchanger.
The controls have a built-in protection function against preventing ice building up in
the heat exchanger.
If the exhaust air temperature falls below + 2°C for more than 1½ hours, the unit
starts to reduce the flow rate of supply air (i.e. RPM on the supply fan are reduced)
until the exhaust air temperature reaches a minimum of + 2°C. Frost protection usu-
ally starts when the outdoor air (T1) is -6 to -7°C or below.
2) Shutdown at an outside temperature below -13°C. If the outside air (T1) falls below -
13°C for more than 5 minutes, the unit will stop completely for 30 minutes. The unit
will then start up again for 5 minutes. If the temperature does not rise above -13°C,
the unit will stop again for 30 minutes, etc.
Recommendation
To ensure balanced ventilation without shutdown Dantherm Air Handling A/S recom-
mends installing pre-heat in areas where the outside temperature will fall below -6°C
for extended periods during the year.
In areas where temperatures are constantly below -13°C, pre-heat is a must to
achieve optimum operation.

14
Service
Preventive maintenance
Introduction
The unit must be serviced at regular intervals to maintain a good indoor climate in the
house, avoid breakdown or inefficient operation and maximise durability. It is important
to note that the intervals between services may vary depending on the environment in
which the unit is installed.
Warning
Disconnect all power to the unit before beginning work!
Only trained and certified engineers are permitted to service the internal parts of
the unit.
Users may replace filters
Ensure that all work is completed and that the polystyrene front cover and the front
cover have been replaced before power is reconnected.
Parts
The following parts must be checked and/or replaced as required:
Filters
Fans
Drip tray and internal surfaces
Drain and discharge pipe
Heat exchanger
Controls
The unit must also be serviced if it suddenly shows signs of unstable operations, vi-
brates, leaks, makes a noise or other faults occur as described in the section on trou-
bleshooting.
Service intervals
The table provides an overview of service intervals for different parts:
Service interval
Task
To be carried out by
0.5 years
Filter check. Change if required
User
External cleaning
User
1 year
Filter replacement
User
External discharge
Certified engineer
2 years
Heat exchanger
Certified engineer
Fans
Certified engineer
Drip tray/internal discharge
Certified engineer
Internal air ducts
Certified engineer
Filters and external
cleaning
Intervals can be adapted to the use of the house and the outdoor air particle and smog
content. See the user guide for details. Filters must, however, be checked every six
months. Dantherm Air Handling always recommends replacing filters at least once a
year.
Check or replace filters when the filter alarm flashes yellow on the control panel while
beeping (once an hour). Always reset the filter timer after a filter replacement by press-
ing the filter reset button next to the filter for 2 seconds.
Clean the unit externally and around the filter openings with a damp cloth to maintain
good hygiene. Filter replacement is described in detail in the user guide
Continued overleaf

15
070719 •Version 1.1 • 05.10.2012
EN
Preventive maintenance, continued
Drain, external con-
nection and piping
Drain, external connection and piping must be checked every year before the risk of
frost occurs.
Check that the pipes are secured to the unit and that there is water in the water trap.
Check that the pipe is not kinked, that there is a minimum gradient of 1% from the unit
to the drain and that the pipe is protected from frost from unit to drain.
Fans
Clean the fan blades every other year using compressed air or a brush. Each fan blade
should be clean in order to keep the fan balanced. Be careful not to remove the balanc-
ing pieces mounted on the fan blades.
Drip tray
Ensure that the condensate drain is not blocked in the drip tray and clean the drip tray
with soapy water and a brush or cloth every other year to ensure good hygiene inside
the unit.
Internal cleaning
Keep the unit clean to ensure seamless operation and good hygiene.
Internal cleaning should only be carried out if the unit is to be opened anyway, e.g. for
other service.
Check the unit's internal surfaces. If they are dirty, they should be cleaned with a damp
cloth, brush, vacuum cleaner, etc.
Heat exchanger
Check the heat exchanger for dirt every other year.
Clean the heat exchanger with a soft brush and a vacuum cleaner at all four inlets.
In special cases, e.g. if there are signs of accumulated, dirty condensate in the heat ex-
changer, it may be necessary to remove the exchanger from the unit and clean the ex-
changer with soapy water.
Continued overleaf

16
Preventive maintenance, continued
Warranty conditions
The factory warranty is only valid with documented preventive maintenance. Mainte-
nance must have been carried out at intervals of a minimum of six months. The docu-
mentation must be in the form of a written log/journal.
Service log
Complete the log at every service visit:
Date
Description of the service carried out/parts replaced
Engineer/initials

17
070719 •Version 1.1 • 05.10.2012
EN
Spare parts list HCV 4
Illustration
Spare parts list illustration HCV 4

18
List HCV 4
Spare parts list including spare parts numbers:
Item
HCV 4
Description
1
063680
Mounting rail
2
062064
Filter reset button, FRB
3
062060
Print MPCB
4
062019
Fan, diameter 133 mm, 650 mm cable
5
062019
Fan, diameter 133 mm, 650 mm cable
6
070760
Cabling, complete set
7
070784
Temperature sensor, cable set, wall
8
070767
Humidity sensor 1150 mm
9
070765
Counterflow cable with plug, 1600 mm
10
062045
Power cable with plug, 1150 mm, P1150
11
062046
Counterflow cable with plug, 1150 mm, MC1150
12
062023
Rail for drip tray, 475x50 mm
13
062063
Supply cable, 230 V AC
14
062059
HCP4 control panel
15
063367
Front cover, bottom
16
063366
Front cover, top
17
062066
Magnet, 64x10 mm
18
062018
Polystyrene front, complete
19
062694
Filter cover
20
070775
Heat exchanger 336 mm with insulation
21
064405
Hinges x 10
22
062062
Connection panel, CP: IEC plug
23
062065
Pressure tube connection for pressure measurement