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Dantherm FB 810-G4-FG-NC Service Manual
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Dantherm FB 810-G4-FG-NC Service Manual

Dantherm FB 810-G4-FG-NC Service Manual

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Flexibox 810 G4-FG-NC
Service manual
Rev. 1.0
EN

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Summary of Contents for Dantherm FB 810-G4-FG-NC

  • Page 1 Flexibox 810 G4-FG-NC Service manual Rev. 1.0...
  • Page 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...
  • Page 3 Copying of this service manual, or part of it, is forbidden without prior written permis- sion from Dantherm A/S. Reservations Dantherm reserves the right to make changes and improvements to the product and the service manual at any time without prior notice or obligation. Table of contents This service manual covers the following main topics: Introduction ........................
  • Page 4 Flexibox 810 is designed to maintain correct temperature for electronic equipment, by removing dissipated heat from the electronics shelter. Important Dantherm recommends that any cooling system should be operating continuously, in order to maintain flawless telecom services around the clock. Outdoor view This illustrates the unit parts Fig.
  • Page 5 Product description, continued Indoor view This illustrates the unit indoor visible parts Fig. 2 Parts description This tables shows indoor parts according Fig. 2 indoor view Part Function Air inlet grill Controller connection Earth connection Flexibox 810 Bracket assembly of the Flexibox 810 dimensions. bracket Flexibox 810 Fig.
  • Page 6 Product description, continued Cooling The Flexibox controller continuously monitors the inside as well as the outside air tem- operation perature, and select appropriate operation mode accordingly. Mode Description External heating If the inside temperature is lower than the heat setpoint (“Heater SetPt.”) parameter, any external heater connected to the Flexibox, will be activated.
  • Page 7 Product description, continued Cooling air flow The illustration and table below describe the free cooling airflow of a Flexibox 810 setup Fig. 4 Cooling Phase Description Cold outside air is drawn into the Flexibox through the air filter, and sup- plied into the warmer shelter Cold air will mix with the warmer air, and push the warmest air towards the ceiling...
  • Page 8 The following accessories is available for Flexibox 810: Part description Part no. Illustration G4 filter, 2 pce. 077164 F5 filter, 2 pce. 840007 F7 filter, 2 pce. 070568 Dantherm RS485 075210 display unit SD Card with collection of Flexibox 810 081212 configurations Motorized damper 074606 400x411mm...
  • Page 9 Accessories, continued Accessory list, con- tinued Air inleet hood with grill 576x663x440mm 299653 For use with 074606 Air inleet hood with grill 1100x220mm 299941 For use with 074607...
  • Page 10 Flexibox installation Introduction The Flexibox unit needs proper installation in order to operate flawless for many years. Please follow this section for proper installation Placement The Flexibox is designed to be mounted outside, as low as possible, thus having a min- imum of 300 mm to the outside ground (even when snow is present).
  • Page 11 Flexibox installation, continued Cut inlet hole Cut by means of proper cutting tools, according to the shelter structure, precisely at the shown measures. Fig. 6 Mount bracket Mount the bracket with at least two appropriate screws, predrill holes for screws if needed.
  • Page 12 Flexibox installation, continued Mount Flexibox Mount the unit onto the bracket, following this procedure: Step Action Illustration Lift the unit onto the bracket Drill at least two holes 1 mm higher diameter than the screws, in the lower rear cover. Mount at least two appropriate screws, to secure the Flexibox to the shelter.
  • Page 13 Place the indoor temperature sensor at the location, most likely to be in the requested sensor temperature area. Dantherm recommend the usage of a handheld infrared thermometer to locate the correct location. Mount the sensor without the sensor housing touching any framework or walls.
  • Page 14 Damper installation Introduction As the Flexibox unit feeds outside air into the shelter, a damper is mandatory, in order to create an balanced air flow though the shelter, pulling out the dissipated heat. The damper can be motorized or non-motorized overpressure type, which open if pres- sure is higher inside than outside.
  • Page 15 Damper installation, continued Mount rain hood Mount the outside rain hood with appropriate amount and type of screws. Predrill if needed Fig. 14 Seal rainhood Seal with a grey Polymer caulking sealing as illustrated Fig. 15 Connection If using a motorized version, connect according the connection schematics shown on page 18...
  • Page 16 Electronic controller Introduction This section describes features of controller, and how it operates. WARNING Never carry out any installation, maintenance or service, without disconnecting the DC power supply, by means of the external power supply disconnecting device. Table of content This section covers the following main topics: Electronic controller ....................
  • Page 17 Controller overall Main PCB The Flexibox 810 has a built in Dantherm CC4 telecom cooling controller, which can be setup to cover almost every cooling needs. Key figures: External connections:  power supply room temperature sensor digital input to force a specific operation (shut down in case of fire) digital output for external heater and AC unit 2 pce.
  • Page 18 Controller overall, continued Start-up When power is connected, the controller boots up that last up to 120 seconds, in which the unit seems to be total off. After 120 second the fans starts and control LED turn on, and the system is running. LED feed back The PCB board has two LED located above the SD card reader close to the PCB board edge.
  • Page 19 Connections Introduction The controller needs only DC power, damper (if motorizes) and indoor temperature sensor connected, to operate in free cooling mode. Full advantages of Flexibox system require additional external units to be connected, changing the controller to be a full-fledged all year room temperature controller Block schematic This illustrates the overall system block schematic, with internal as well as external con- nection’s...
  • Page 20 Connections, continued Connection This illustration shows the external connections. schematic External safety br eaker (not included) 10A Mini blade terminal. FX ”Littlefuse” type ”997 010 ” 1: Red, +48V DC 48V DC negative 2:Yellow, Fan PWM 3:White, Fan tacho 48V DC positive 4:Blue, GND EBM fan -t°...
  • Page 21 Power Box Schematic...
  • Page 22 The damper output feeds the damper motor with 40-60Vdc/ max. 100mA J16 / 17 RS485 – RTU Modbus. RS 485 J17 can supply the Dantherm display unit with power. Communication data: baud rate - 9600 data bits - 8 parity - none...
  • Page 23 Controller operation strategy Introduction The controller is pre-programmed from factory with default parameters covering the most common setup. These can be changed to specific needs. In order to do so, it’s mandatory to know how these affect each other. Main decisions When installing the Flexibox it’s imperative to decide if the Flexibox system needs addi- tional AC connected or not, as this influences quite a lot on the cooling strategy.
  • Page 24 Controller operation strategy, continued Function strategy This shows the universal controller operation mode depending on temperature in sys- without AC tems without AC connected. Fan control This illustration shows the universal controllers fan control depending on temperature. strategy The idle mode isn’t present in Flexibox: Fig.
  • Page 25 Introduction This section will guide you through each parameter. We strongly recommend using the Dantherm display unit to change the basic cooling and heating set points or obtain and load one of the standard parameters packages. Both options are Dantherm accessory ONLY qualified personnel should change each specific parameter below.
  • Page 26 Changing parameters, continued Cooling fan configu- The first section in the parameters file covering parameter 1 to 9, controls the setpoints ration, 1-9 for which the fan changes speed. 2 not active Example. 1=Flexibox fan 3 not active See strategy Cooling Fan Configuration Fan 1 Fan 2...
  • Page 27 Changing parameters, continued Damper The second section in the parameters file is covering Damper parameter 1 to 11 con- configuration trolling any motorized damper. 1 not active active Example. Damper Configuration Damper 1 Damper 2 1.LOWER Close Temp [dT0][-40-80]: 20.0 : 20.0 2.SET POINT [dTs][-40-80]: 24.0...
  • Page 28 Changing parameters, continued Compressor/AC The third section in the parameters file is covering AC parameter 1 to 12 controlling any Configuration external connected Air Conditioner Flexibox 2 not active not active AC output Example. Compressor/AC-Unit Configuration Comp A/C 1 A/C 2 1.ON Temp [cT0][-40-80]: 32.0 : 32.0...
  • Page 29 Log interval in min. Logging interval on SD card .RS-485 Bus Pow. RS485 power out. Disable if using Dis/Ena J17/ RS-485 with non Dantherm display. ModBus Slave Addr Set the device adresse if having more devices in order to avoid...
  • Page 30 Changing parameters, continued Alarm mapping The last section in the parameters file is covering overall handling of system alarm events. Example. RED LED on the PCB´s edge is lit, if any of the alarms states are active on any of ...
  • Page 31 Digital input Introduction The Flexibox system can be setup to operate in a large variety of situations depending on the temperatures measured. In other operation situation, it can bring value to force a specific operation, e.g. in case of a fire, where the unit and damper needs to be shut down, and thereby minimizing the amount of incoming oxygen to the fire.
  • Page 32 Service guide Overview  Introduction This section gives all relevant information about servicing, spare parts and trouble shooting. Serial numbers Product model and serial numbers are found on the nameplate. Please have product model and serial numbers ready if you are contacting After Sales Support.
  • Page 33  Maximum 12 months when unit is located in normal air quality areas  Maximum 6 months when unit is located in dirty areas, fx close to roads. Dantherm recommend that unit are examined closely during the first preventive maintenance, to determine whether the service interval is too long. Filter alarm...
  • Page 34 Preventive maintenance, continued Cleaning The unit must be cleaned according to the recommended preventive maintenance plan. Tools required: Vacuum cleaner or compressed air  Soft brush  TX20 screwdriver  Cleaning agent if it´s very fealty  Phase Description Open the units cover, and remove the old filter Remove any leaves trapped in the air inlet safety grill Check previous service log for fan failures or replacements.
  • Page 35 Troubleshooting Introduction Operating errors may occur. Follow this flowcharts for a possible solution Fault: No visible or audiable  Fan off running indication. Fan  stopped =YES Recover possible  alarms (red LED on) Still faulty? Correct and connect Power connected  (positive/negative  correctly and present ?  swap? ) Remove all connectors  Green LED on PCB  on  but 48v DC Replace CC4 controller (after 120s) ?  Green LED on(after  120s) ? Short circuit in one of the  external connections.  Connnect one by one  watching the green LED AC or HEAT output  Store parameters on ...
  • Page 36 Spare part list Illustration Available spare parts for Flexibox 810: Fig. 19 List List of spare parts including spare part numbers: Pos. Description Temperature sensor 2600 mm cord (indoor and ambient) 036761 Filter guard monitor 840020 CC4 controller for Flexibox 810 (NC configuration) 099362 Fan for Flexibox 810 077161...
  • Page 37 Replacing parts Introduction This section covers the replacement of parts WARNING Never carry out any installation, maintenance or service, without disconnecting the AC power supply, by means of the external power supply disconnecting devices. Parts replacement Follow these steps to replace various parts Step Action Illustration...
  • Page 38 Technical data Introduction This section covers technical data and dimensions for Flexibox 810. Technical data This table shows the technical data for the Flexibox 810 Flexibox 810 Specification Unit Nominal air flow m³/h 2020 Maximum air flow m³/h 2430 Nominal Cooling capacity in W / K W / K (Δt=1°C) Estimated Boost mode Cooling capacity...
  • Page 39 Technical data, continued EC-Declaration of Dantherm A/S, Marienlystvej 65, DK-7800 Skive hereby declare that the Flexibox 810 is in conformity with the following directives: Conformity 2006/42/EC Directive on the Safety of Machines 2014/35/EU Low Voltage Directive 2014/30/EU EMC Directive 2014/26/EU...
  • Page 40 Technical data Introduction The tables below show the factory supplied settings. Default parameters °Dantherm A/S., Skive, 7800 DENMARK Controller - Flexibox 810 SW Ver - 2.0 Flexibox 810 - NC ----------------------------------------------------------- *special configuration Flexibox 810 * *Poweride* updated 25.10.18 by KH...
  • Page 41 Technical data, continued , continued ----------------------------------------------------------- Heater Configuration 1.ON Temp [hT0][-40-80]: 12.0 2.OFF Temp [hT1][-40-80]: 14.0 3.Override - Digi.1 [x/0/1]: 0 4.Override - Digi.2 [x/0/1]: x 5.Override - Sensor Fail [x/0/1]: 0 6.Sens.Sel. OB/RM/AM/SP/CD [0-4]: 1 7.Enable [xDe][0/1]: 1 ----------------------------------------------------------- System Control Configurations 1.Norm.
  • Page 42 Index 460 versus 810 ............. 3 fan strategy ..............22 AC configuration ............26 function strategy ............21 accessories ..............6 heater configuration ............ 26 airflow ................5 indoor temperature sensor .......... 11 alarm mapping ............28 inspection ..............32 alarms .................
  • Page 44 Phone +1 (864) 595 9800 Mobile +971 56 831 7466 Direct +45 60 23 55 29 +44 (0)1275 34 30 86 +1 (864) 595 9810 infouk@dantherm.com infous@dantherm.com frb@dantherm.com www.dantherm.com www.dantherm.co.uk www.dantherm.com Dantherm Air Handling A/S Marienlystvej 65 7800 Skive Denmark www.dantherm.com service@dantherm.com...