Professional Documents
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Service manual
EN
No. 062367 rev. 1.0 15.02.2011
DA EN
DE
Side Page
3 23
FR
Der tages forbehold for trykfejl og ndringer Dantherm can accept no responsibility for possible errors and changes Irrtmer und nderungen vorbehalten Dantherm nassume aucune responsabilit pour erreurs et modifications ventuelles
Introduction
Overview
Introduction This is the service manual for the Dantherm Air Handling A/S AC-M5 W MKII unit. The below table of contents gives an overview of the main sections.
Serial number
This manual covers units with serial numbers equal or higher than: XXXXXX1158513
Syntax
Please note that this unit comes as standard with a 2 KW heating element installed: Dantherm number 322036
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Code
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AC-M5WE-H020-B-BS381C285
The code is specified on the data plate, which is placed on the outside of the unit. See the explanation of the syntax code on page 5
Warning
It is the responsibility of the operator to read and understand this service manual and other information provided and to use the correct operating procedures. Air conditioners should only be operated by qualified (trained) personnel and the repair of the cooling circuit and electrical system is to be done only by skilled service people. Failure to do so can result in personal injury or equipment damage. Read the entire manual before the initial start-up of the air conditioner. It is important to know the correct operating procedures for the air conditioner and all safety precautions to prevent the possibility of property damage and/or personal injury.
Table of contents
This service manual covers the following main topics: Topic General information Syntax Product description Functional description Users guide Service guide Technical information See page 4 5 6 15 16 25 36
General information
Introduction This section gives the general information about this service manual and about the unit.
Target group
The target groups for this service manual are the: Users of the unit Technicians who install and maintain the unit
Copyright
Copying of this service manual, or part of it, is forbidden without prior written permission from Dantherm Air Handling A/S.
Reservations
Dantherm Air Handling A/S reserves the right to make changes and improvements to the product and the service manual at any time without prior notice or obligation.
EC-Declaration of Conformity
Dantherm Air Handling A/S, Marienlystvej 65, DK-7800 Skive hereby declare that the units mentioned below: AC-M5 W MKII, product no. 322036: are in conformity with the following directives: 2006/42/EEC 2006/95/EEC 2004/108/EEC 97/23/EEC 94/62/EEC EN 12100 EN 60 335-1 EN 60 335-2-40 DEF-STAN 59-411, part 3 Land Class C EN 378 Skive, 16.09.2009 Directive on the safety of machines Low Voltage Directive EMC Directive The Pressure Equipment Directive Packaging Directive Machine Safety Low Voltage Low Voltage Military EMC Standard Refrigeration systems
Recycling
The unit is designed to last for many years. When the time comes for the unit to be recycled, the unit should be recycled according to national rules and procedures to protect the environment.
Dantherm Air Handling A/S has implemented a Quality Management System according to EN/ISO9001. The system is supplemented with an Environmental Management System according to EN/ISO14001. Both systems are third-part approved and certified, by Bureau Veritas Certification. During 2005 & 2006 the Management Systems are supplemented with businessroutines with regards to Safety. These routines fulfil the requirements stated in the international standard for Safety Management Systems OHSAS18001.
Syntax
Introduction All products are named according to a syntax giving information about the specific unit configuration.
Example
This example is not necessarily related to the specific unit this manual describes:
AC-M5W-H070-B-225-R6014-G3F7-SH-X1
AC VA
Military unit
5 kW nominal performance
W S
Electric heat
A B C D E F
1 ph; 115 V AC; 60 Hz 1 ph; 230 V AC; 50 Hz 1 ph; 230 V AC; 60 Hz 3 ph; 230 V AC; 60 Hz 3 ph; 460 V AC; 60 Hz 3 ph; 400 V AC; 50 Hz
R6014 Four digit RAL colour code or 33446 FED-STD 595B code
G3F7
S H
Specifics/custom
Product description
Overview
Introduction This section will give you a description of the AC-M5 W MKII and its functionality.
Content
The section covers the following topics: Topic General description Description of the cooling system Description of the control board Accessories See page 7 10 12 14
General description
Introduction This section gives a description of the unit as a whole. The following sections describe the different parts in detail.
General
The AC-M5 W MKII air conditioner is made of high quality materials and the production process is subject to constant quality checking. The instructions in this service manual have been prepared to ensure that, when followed, this air conditioner will provide long and efficient service.
Typical applications
The AC-M5 W MKII is designed to be built into a trap door system, which is mounted in the container. Optionally in welding frame. The AC-M5 W MKII is designed to be compatible with shelters equipped with existing AC-M5 W. All dimensions are translated into the new design. This easily upgrades the container to AC-M5 W MKII. Dantherm air conditioner model AC-M5 W MKII is designed primarily to deliver cooling or heating to containers and other types of temporary shelters. Other typical applications can be: Cooling of hot confined areas where personnel are working Cooling of equipment to prevent damage or malfunction due to overheating Re-circulating air in closed shelters
Functionality
The function of the AC-M5 W MKII is based on a cooling circuit and two powerful fans. The front section (internal) contains the evaporator and the evaporator fan, which draws warm ambient or re-circulated air through the cold evaporator coil and blows out the cooled air through the discharge. The back (external) section of the unit houses the condenser fan and the condenser coil, which returns the heat taken from the indoor air to the surrounding atmosphere.
Lifting system
By means of a fork lift the air conditioner is lifted from the outside and in, into the trap door system. Components on the below drawing from left to right: Front grill Welding frame Trapdoor system AC-M5 W MKII
Continued overleaf
Top view
Part
Function Recirculated air intake Discharge of cooled air in container Condenser air intake Condenser air discharge Evaporator
Part Condenser
Function
Heater
062367 Version 1.0 14.02.2011
The heater coils installed are equipped with a reset button for OT (overheating) thermostat on top of the unit. For reset of the OT, please see section Fault finding guide, page 33
Built-in thermostat The AC-M5 W MKII has a built-in thermostat which monitors the return air temperature. The temperature is set on the dial on the control board.
Illustration
This illustrates the cooling system and internal components of the AC-M5 W MKII:
Continued overleaf
10
Schematic view
This schematic drawing illustrates the different parts of the cooling circuit:
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Part
Function Expansion valve Evaporator HP pressure switch Schrader valve Heating element
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Illustration
Part/function
This table gives an overview of each part of the control panel: Part Function switch Function The function switch selects the operating mode. For a detailed description of the modes please see section Functional description, page 15
Switch for high or low evaporator fan speed: Speed low/I Description Normally used if the noise level should be low and the maximum cooling/heating capacity is not required Normally used if a maximum cooling/heating capacity is required
high/II
Continued overleaf
12
Function On the operator panel there are 4 control lamps, indicating the following from left to right: Symbol Green Cooling Yellow Red Color Description IR connection to serial port. For Dantherm service technician only Cooling circuit is operating to lower temperature. Normal operation is green The unit is operated inefficiently. This will self reset in time The compressor current draw is outside specified window. (indicating a faulty compressor) This will reset when functions switch is briefly switched to off position Green Power Always green, provided there is 230 V AC connected to the unit. Note: Also green when the functions switch is in Off position Must be completely off when servicing unit/changing filter Green Heating Red Indicating the heater coil is working to raise temperature The heater coil current draw is outside specified window. (indicating an open circuit like OT fault) This will reset when functions switch is briefly switched to off position, and/or the OT reset button is depressed. OT fail: Overheat thermostat failure. See also section Fault finding guide, page 33 Green Red Fan operation whenever one or both fans are running One or both fans have a defect chasing the current draw out of specified window
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Accessories
Introduction Further information about each separate accessory is available upon request to Dantherm Air Handling A/S.
List
Below you will find a complete list with drawings, description and article numbers of available accessories: Accessory Trap door system Illustration Description Trap door system
Article No./ NSN No.
322037/-
Frame
019502/-
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Functional description
Function switch The function switch allows the user to switch between different modes. The modes are described below.
Operation modes
This gives a description of each selectable mode: Mode Ventilation operation Description The evaporator fan will operate according to the speed selected on the evaporator fan speed switch
O (OFF)
All functions will immediately stop and only the illuminated green lamp will indicate that the power is still on. Warning: The evaporator fan will run according to speed selector, even with the mode selector in 0 OFF position, if temperature inside the AC-M5 W MKII cabinet exceeds 50 C. This will automatically shut down when temperature inside the AC-M5 W MKII cabinet drops below 35 C
AUTO
The controller will operate to achieve the selected temperature set on the temperature dial. The controller decides whether to activate cooling or heating, in order to maintain desired temperature.
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Users guide
Overview
Introduction This section describes how to utilise the different functions.
Compressor protection
The compressor unit is protected from start up overheating. This is done by introducing a 30 sec start up delay on compressor start up on every cooling cycle start. Rapid adjustments of temperature dial will prevent the compressor from starting. DO NOT cycle the temperature dial as this will cause the cooling to NEVER come on.
Contents
This section contains the following topics: Topic Make the AC-M5 W MKII ready for use ACU removal Starting up and shutting down the air conditioner Transport and lifting of the unit See page 17 21 22 24
16
4 5 6
Follow these steps to install the unit in the door trap system: Step 1 Action Remove the door from the trap door system by removing the two Allen screws that hold the door
Continued overleaf
17
Step 2 Loosen the 21 screws that hold the front grill. Dismount the front grill and the filter
Action
4 5
Push the ACU gently into the trapdoor. Care should be taken to ensure that the power cable is not snagged when the ACU is pushed inwards Align the two M8 holes roughly with the big 25 mm holes in each horn when pushing in the ACU
Continued overleaf
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Step 6 Screw in loosely the two 8 mm finger screws dangling in wires on each horn. This is to secure the ACU while re-mounting the front grill. It is also the way to secure the ACU during filter change/cleaning Care should be taken to avoid damage to your fingers when performing this task 7 8
Action
Remount the filter, the front grill and the 17 screws. Do not remove the two M8 finger screws just yet Mount the 2 draw out roller mechanisms (delivered separately in a small bag) as shown in the pictures in step 5 and 6
Continued overleaf
19
Step 9 Next mount the buffer consoles. One for each side
Action
10 11
Connect power Re-mount the door of the trap door system and shut it securely using the snap locks from the outside of the shelter
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ACU removal
Procedure Follow this procedure to remove the ACU: Step 1 2 3 4 Action Switch off the ACU and remove the power cable from the shelter connection Ensure ACU is in the filter change/service position, with the securing knobs loosely fitted in the large holes in the horns Unscrew the 19 torx 15 screws and detach the front grill of the unit Remove the filter and the exhaust/discharge grill Do not harm the EMC seal in the front grill 5 6 7 Stowed away the power cable inside the ACU for convenience Remove the flap from the door trap system by removing the two Allen screws that hold the door Unscrew the securing knobs. Push the ACU by hand onto the forks of a forklift, placed on the outside of the shelter. Be careful not to harm the power supply cable. Alternatively the power cable can be coiled and placed inside the cabinet in these steps. Do not harm the EMC seal on the trapdoor 8 Strap the ACU securely to the forks while descending to the ground. Do not forget the power cable as this is the only cable connected to the ACU at this point Remount the front grill and discharge grill to the ACU by the 19 torx 15 screws Take care of the EMC seal in the front grill Remount and securely close the flap of the door trap system with the snap catches on the outside of the shelter. NOTE: The trap door itself, without the ACU (but with the door/flap fitted), does not provide Land Class C attenuation, according to DEF-STAN-59411
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Before starting up Before starting the AC M5W, the unit has to be brought into the deployed position. Follow this procedure: Step 1 Action Release the two snap catches on the outside of the shelter, which are holding the flap of the trap door system in place. If installed unhook the locking pin from the centre of the door/flap Release the two hand screws at the side of the horn Now the unit can be pushed out and secured with the set of snap catches 3 Park the two hand screws in the threaded insert in the front grill with the unit deployed. The positions for hand screws, left to right: (the tip of the horn to the base) 1) Transport position. Hole at the end of horns. 2) Filter change/service position. (Large hole) 3) Parking spot when unit is operation (Obround hole)
Start up
With the preplanning complete, the air conditioner is ready for operation: Follow the procedure below to start up the air conditioner: Step 1 Action Turn the function switch to the desired mode (see Description of the control board, page 12) and the unit will operate according to the Functional description, page 15 if not switched off by a safety device.
Fault
If the unit does not operate it might have been switched off by a safety device: HP pressure sensitive switch: An ambient temperature higher than the working range 20C-60C will cause the condenser not to be cooled enough, resulting in excessive pressure in the cooling circuit and thereby a cut out by the HP pressure sensitive switch. A reduced airflow through the condenser core can result in cut-out of the high pressure (HP). Evaporator or condenser fan thermo relay: Running current for the fan motor is too high
Continued overleaf
22
Shutting down
Follow this procedure to shut down the air conditioner from any mode of operation: Step 1 Action Turn the function toggle switch to OFF Result: All operations stop instantly Warning: The evaporator fan will continue to operate, or start up, even with the function switch in zero position, if the temperature inside the ACU exceeds 50 C. The fan stops, with the function switch in zero position, as soon as the temperature drops below 35 C 2 3 Release the two snap catches and unscrew the two hand screws, from their parking position and pull the unit back into the container Secure the door of the trap door system by means of the two snap locks on the outside of the shelter and secure the ACU by the two hand screws at the tip of the horns. If the shelter is to be transported under slung by helicopter, mounting the safety pin of the trap door system is mandatory. Disconnect the power cable at the power supply and coil the cable if: the air conditioner is put aside for a longer period or if service is to be performed
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By means of a forklift is possible to lift the unit to the right height and to push it into the trap door system from the outside of the container. Note that this is only possible with the front grill assembly detached.
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Service guide
Overview
Serial numbers This section gives the necessary information to help the responsible maintenance personnel at servicing and repairing the air conditioner. All requests for information, service or parts should include the serial number. Product model and serial numbers are available from the data plate which is located on the right side of the unit.
Contents
This section covers the following topics: Topic Preventive maintenance Spare parts Fault finding guide Service agreement See page 26 29 33 35
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Preventive maintenance
Introduction In order to achieve the best possible operation and long lifetime of the air conditioner it has to be maintained properly within defined guide lines. This section contains the description of daily, monthly and annual maintenance.
Tools
For service and maintenance a torx 15 screwdriver and a 10 mm spanner or socket wrench is required.
CAUTION
Before doing any maintenance, be sure that the air conditioner has been shut down and that the power cable is disconnected from the power supply. See section Starting up and shutting down the air conditioner, page 22.
Recommendations In addition to the preventive maintenance it is recommended to have a cooling technician check the cooling circuit and all electrical functions. This check must follow the national rules for control of cooling equipment.
Preventive maintenance to done on a daily basis or every 8 hours of operation: Perform the following preventive maintenance procedures each day or after every eight hours of operation: Step 1 2 Action Inspect the power cable for damage or loose connections Inspect the air filter and remove any debris or foreign objects that may have accumulated on the filter
Continued overleaf
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3 4 5 6 7 8
062367 Version 1.0 14.02.2011
Loosen the two latches in each side of the unit Grab the handles Fasten the screws (one in each side) and pull the unit into the container (one in each side) to fix the unit to get access to
Grap the filter behind the frame and clean it with a hoover or wash in luke warm soap water Check that the condensate drain is not blocked. Use high pressure air from the outside of the unit for 5 seconds to remove dirt. Condensate drain pipe Follow the above steps just in reverse order to remount the unit Make sure that the filters are dry before they return to service again and are subjected to dust
Continued overleaf
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4 5 6
Dismount the front frame by unscrewing 16 torx 20 screws to the filter Dismount all 21 screws on the top cover
to get access
Inspect the evaporator and condenser coils. If they are dirty, then clean with a hoover or wash with warm soap water and a brush Lift up the internal fan module 7-10 cm to get better access to the evaporator Before being able to lift the fan module you need to unscrew 2 screws between the fan house and the coils Clean the drip tray Inspect and if necessary clean the radial wheels in the two fans Follow the above steps just in reverse order to remount the unit
7 8 9
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Spare parts
Introduction This section contains the general information needed when ordering spare parts. For units in military services spares will normally be ordered through the military logistic system. The spare parts lists are available on the following pages.
When ordering
When ordering, kindly inform us about: Dantherm Air Handling A/S spare parts number/text NATO stock number of parts Dantherm Air Handling A/S field unit type Dantherm Air Handling A/S production and serial number from the data plate of the field unit (or approximate date of delivery).
Information
Not every item will be available for delivery individually, if it is part of a group naturally forming a whole or part of a purchased, complete component. Dantherm Air Handling A/S reserves the right to make this assessment.
Reservations
Dantherm Air Handling A/S reserves the right to make any necessary changes of construction and choices of components without notice - but will, as far as possible, maintain a stock of the changed parts.
Continued overleaf
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Fig. 2
Continued overleaf
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Part No. 063108 063109 066668 063111 063112 063113 063114 063115 063116 063117 063118 063119 063120 063121 063122 063123 063124 063125 063126 063127 063128 063129 063130 063131 063132 063133 063134 063135 063136
Nomenclature Cover complete with insulation Evaporator coil Heating 2000 W complete Fan and fan housing complete, evaporator Fan, evaporator Drip tray with drain tube components Handle, set with 2 pcs. Grill, internal side Front gable, complete Filter Base plate, complete Fan and fan housing complete, condenser Fan, condenser Condenser coil Sensor, set with 2 pcs. Inspection glass Expansion valve Service valve Switch, high pressure Compressor Receiver Dry filter Control box complete Capacitor 5F Capacitor 40F Capacitor 2,5F
NATO No. 1670-22-620-0246 4130-22-620-0248 4520-22-620-0249 4120-22-620-0312 4140-22-620-0250 9999-22-620-0251 5340-22-620-0253 5340-22-620-0256 5340-22-620-0255 4130-22-620-0257 1670-22-620-0259 4140-22-620-0261 4140-22-620-0263 4130-22-620-0265 6685-22-620-0266 6680-22-620-0316 4820-22-620-0267 4820-22-620-0268 5930-22-620-0270 4130-22-620-0271 4130-22-620-0272 4130-22-620-0273 4130-22-620-0274 5910-22-620-0275 5910-22-620-0276 5910-22-620-0277
Front label, cable entry, switches and 5975-22-620-0278 potentiometer Control box bottom Rubber grommet set 6110-22-620-0279 5365-22-620-0280
Continued overleaf
28 29
31
32
Air conditioner does not operate. Power indicator lamp is green. Cool light is green and turns yellow
High ambient temperature resulting in HP pressure sensitive switch cut-out (automatic reset) or low pressure conditions are detected
Continued overleaf
33
Problem No heating action possible. Power light is green. Heat indicator lamp is red.
Action Allow temperature to drop before pressing the reset button on top of ACU
Internal temperature protection in either condenser or evaporator fan motor has cut-out
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Service agreement
Introduction The unit includes mechanical and electrical parts and the unit is often placed in a rough environment where the components are exposed to different climate conditions. Therefore the unit will need preventative maintenance on a regular basis.
Hotline
The After Sales Support Department of Dantherm Air Handling A/S is ready to help you in case of a problem. To be able to offer quick and efficient help, please have the following information ready when contacting Dantherm Air Handling A/S: Name Company Country Phone no. Email Type (unit) Site/location (unit) Serial no/order no. Description of the problem
Contact Dantherm Air Handling A/S, ask for the After Sales Support department and help will be provided as soon as possible: Phone: +45 96 14 37 00 Fax: +45 96 14 38 00 Email: service@dantherm.com
Preventive maintenance
Dantherm Air Handling A/S offers to do the preventive maintenance on the units so that they at all times will operate according to factory standards.
In case of malfunctions of the product Dantherm Air Handling A/S offers to do emergency repair on the climate units. Agreements will be made with the customer on response time and price.
Setup
Dantherm Air Handling A/S has established a network of service partners to do the preventative maintenance. The partner is trained and certified on the actual climate units. The partner will also carry an adequate number of spare parts so that any repairs can be made during the same visit. The agreement will be made with Dantherm Air Handling A/S and the overall responsibility for the agreement will be Dantherm Air Handling A/Ss.
Further information
For further information about a service agreement in your country or region, please contact: Henrik Hersted After Sales Support Manager Dantherm Air Handling A/S Phone: +45 9614 4767 Mobile: +45 2399 4066 Email: heh@dantherm.com
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Technical information
Overview
Contents This section covers the following topics: Topic Technical data Dimensions Wiring diagram References for the wiring diagram See page 37 38 39 41
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Technical data
Introduction Technical data for the AC-M5 W MKII unit.
Performance characteristics
The air conditioner has a maximum cooling capacity of 4.7 kW. When the relative humidity of the air inlet is high, the air can be cooled below its dew point and thus condense some of the water vapour to free water. This requires a certain amount of latent cooling but provides a dehumidification process, which is an important factor in comfortable air supply conditions. The operating range is between 20 and 60 C approximately and is controlled by the HP-pressure switch. In relatively dry locations the air temperature drop will depend on inlet conditions.
Data
Data and dimensions on the cabinet are shown in the following table: Specification Voltage/PH/frequency Electric consumption, max. Cooling capacity, max. Heating capacity (option) Airflow low, evaporator Airflow high, evaporator Airflow, condenser Refrigerant/Load Max. refrigerant pressure Operation temp. range Weight Noise level (1 m) low speed Noise level (1 m) high speed
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Value 230 V 1 PH/50 Hz 2.4 kW/11.2 A 4.7 kW 2.0 kW/8.6 A 420 m/h 900 m/h 1475 m/h R134a/1.4 kg 28 Bar 20-60 C 79 kg 49/48 dB(A) 64/63.5 dB(A)
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Dimensions
Illustration This illustrates the unit dimensions (mm):
38
Wiring diagram
Wiring diagram, a This is the wiring diagram for the unit, references are available on page 41:
Continued overleaf
39
40
Description Electrical heat 2x1000 W/230 V Compressor ZR 22 K3E-PFJ RC unit 470n + 47R X2 Capacitor for compressor 40 MF/400 V Condenser fan EBM A4E350 Capacitor for condenser fan Condensate pump Blue Diamond
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Capacitor for evaporator fan 5mF/450 V low speed Evaporator fan EBM R4E280 Capacitor for evaporator fan 2,5 mF/450 V Limit air temperature sensor heat/fan Return air temperature sensor Test button (only for service) High pressure switch with auto reset Fan speed selector high-low Temperature set point Function selector Auto-Off-Fan
Option
41