AC-M5 W MKII Service manual EN No. 062367 • rev. 1.0 • 15.02.2011
DA
Betjeningsvejledning DVC-styring
Side
3
EN
User’s guide for the DVC controller
Page
23
DE
FR
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
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
Code
AC-M5WE-H020-B-BS381C285
NATO stock number -
*)
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
See page 4
Syntax
5
Product description
6
Functional description
15
User’s guide
16
Service guide
25
Technical information
36
062367 • Version 1.0 • 14.02.2011
General information
3
General information Introduction
This section gives the general information about this service manual and about the unit.
Manual, part number
Part number of this service manual is 062367.
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
Directive on the safety of machines Low Voltage Directive EMC Directive The Pressure Equipment Directive Packaging Directive
- and are manufactured in conformity with the following harmonized standards: EN 12100 EN 60 335-1 EN 60 335-2-40 DEF-STAN 59-411, part 3 Land Class C EN 378
Machine Safety Low Voltage Low Voltage Military EMC Standard Refrigeration systems
Skive, 16.09.2009
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.
Quality Management System
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.
4
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
Air conditioner Heater (diesel)
M
Military unit
5
5 kW nominal performance
W S
Window mount Split unit
H
Electric heat
020 070 100 200
2000 W heat 7000 W heat 10000 W heat 20000 W 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
225 315 400
225 mm connection 315 mm connection 400 mm connection
062367 • Version 1.0 • 14.02.2011
R6014 Four digit RAL colour code or 33446 FED-STD 595B code
G3F7
Two filters, one G3, one F7
S H
Compressor softstarter included HPFI included
X
Specifics/custom
5
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
6
See page
General description
7
Description of the cooling system
10
Description of the control board
12
Accessories
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
062367 • Version 1.0 • 14.02.2011
• AC-M5 W MKII
Continued overleaf
7
General description, continued Cabinet
The unit is a strong construction made in 0.9 mm sheet metal plates, which are galvanised and protected against corrosion. Outside finish painting is standard NATO green, RAL6014 with infrared anti-reflecting qualities. The condensate drain is located under the unit. It is snapped in place by a snaplock in the long slot at the bottom of the unit. The drain can be pried out using a screwdriver if needed during service or if a hose extension is desired. At the front of the unit there is a removable air filter for the recirculated air intake on the left hand side and a discharge grill for the cooled outlet air at the right hand side.
Front (evaporator side)
The operation panel for the unit is placed under the discharge grill for the cooled air. The discharge grill can be removed for inspection and service purposes.
Rear (condenser side) Continued overleaf
8
General description, continued Air flows
Only the Air flowing through the evaporator core enters through a standard washable, removable air filter. On the discharge side of the evaporator section there is a discharge grill. This grill is non adjustable as not to compromise the Land Class C Noise level, described in DEFSTAN-59-411. As the AC-M5 W MKII is unavailable with fresh air intake the air being processed in this unit is re-circulated air within the shelter.
e h j f
f
i k g c Part
062367 • Version 1.0 • 14.02.2011
Heater
d
Top view
Function
Part
Function
c
Recirculated air intake
h
Condenser
d
Discharge of cooled air in container
i
Centrifugal fan
e
Condenser air intake
j
Axial fan
f
Condenser air discharge
k
Heater element
g
Evaporator
-
-
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.
9
Description of the cooling system Description
In the front section of the unit the evaporator (cooling coil) is mounted together with an expansion valve and the sight glass. The condenser, the compressor and the rest of the components are housed in the rear section. The cooling circuit is completely sealed and filled with refrigerant (R134a). Description of the cooling process: From the receiver liquid refrigerant will flow under high pressure through the liquid line dryer and the sight glass to the thermostatic expansion valve. Here the refrigerant is led into the evaporator where it evaporates at low pressure and low temperatures. The evaporated refrigerant is drawn back to the hermetic compressor and compressed. From the compressor the refrigerant vapour goes to the condenser, where it is cooled to below dew point and condensed to liquid refrigerant because of the cooling effect from the condenser airflow. Both evaporator and condenser are heat exchangers with copper tubes and coated aluminium fins. By the cooling of the evaporator air stream heat is adapted to the cooling circuit and released in the condenser together with the electric energy consumption of the compressor. At ambient temperatures below 18-20 °C, where cooling is not normally required, the humidity in the airflow will form ice on the evaporator. This will generate a Low pressure (LP) condition. The compressor will stop until the ice has melted. At high ambient temperatures (above 60 °C) the cooling of the condenser airflow will be too low, and the high pressure results in cut out of the HP pressure switch.
Illustration
This illustrates the cooling system and internal components of the AC-M5 W MKII:
d
f g
e
i h
c
j Continued overleaf
10
Description of the cooling system, continued Parts and their function
This table gives an overview and short description of each part shown in the previous illustration: Part
Schematic view
Function
c Evaporator
Absorbs heat from the shelter by cooling down the circulated air
d Condenser
Emits the heat generated in the tent/room to the outside air
e Centrifugal fan
For internal air flow
f Axial fan
For external air flow
g Compressor
Circulates the fluid in the cooling system
h Expansion valve
Supplies the correct quantity of coolant into the evaporator
i Sight glass
Enables a visual check of the coolant
j Control panel
Control panel with function switch and indicator lamp(s)
This schematic drawing illustrates the different parts of the cooling circuit:
10
Fig. 1
062367 • Version 1.0 • 14.02.2011
Part
Function
Part
Function
c
Compressor
h
Expansion valve
d
Condenser
i
Evaporator
e
Receiver
j
HP pressure switch
f
Liquid line drier
k
Schrader valve
g
Sight glass
l
Heating element
11
Description of the control board Introduction
This section gives a detailed description of the control board. A description of how to start up, for example, is found in section “User’s guide”, from page 16. The control panel on the front side contains all the controls required for normal operation.
Illustration
This illustrates the control board of the AC-M5 W MKII:
g
c
d
f
e Part/function
This table gives an overview of each part of the control panel: Part
Function
c Function switch
The function switch selects the operating mode. For a detailed description of the modes please see section “Functional description”, page 15
d Evaporator fan speed switch
Switch for high or low evaporator fan speed: Speed low/I
high/II
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
Continued overleaf
12
Description of the control board, continued Part/function, continued
Part e Indicator lamps
Function On the operator panel there are 4 control lamps, indicating the following from left to right: Symbol
Color
Description
-
IR connection to serial port. For Dantherm service technician only
Green
Cooling circuit is operating to lower temperature. Normal operation is green
Yellow
The unit is operated inefficiently. This will self reset in time
Red
The compressor current draw is outside specified window. (indicating a faulty compressor)
Cooling
This will reset when functions switch is briefly switched to off position Green Power
Heating
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
Indicating the heater coil is working to raise temperature
Red
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
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Fan operation
Green
whenever one or both fans are running
Red
One or both fans have a defect chasing the current draw out of specified window
f
Temperature dial for room temperature
g
Power cable
13
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: Description
Article No./ NSN No.
Trap door system
Trap door system
322037/-
Frame
Frame for welding into corrugated container
019502/-
Accessory
14
Illustration
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
Description
Ventilation operation
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 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.
062367 • Version 1.0 • 14.02.2011
AUTO
15
User’s 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
16
See page
Make the AC-M5 W MKII ready for use
17
ACU removal
21
Starting up and shutting down the air conditioner
22
Transport and lifting of the unit
24
Make the AC-M5 W MKII ready for use Tools
List of tools required: • 5 mm Allen key • TX 15 screwdriver • 10 mm spanner or socket wrench
Trap door system
Read this recommendation before installing the trap door: Step
Action
1
With an angle grinder, remove rust and oxide scales from the contact surface of the welding frame. Important: Keep grinding until the surface is blank.
2
Degrease and clean the contact surface. Use alcohol or the like.
3
Cover the contact surface with a layer of zinc or a similar anodic solution. Important: Follow the guidelines on how to use the solution (in regard to drying).
4
When the corrosion protection is ready, mount the trap door in the welding frame.
5
Make sure all bolts are surely tightened.
6
When mounted, carefully seal the opening between the welding frame and the trap door to prevent moist from penetrating.
Follow these steps to install the unit in the door trap system: Step
062367 • Version 1.0 • 14.02.2011
1
Action Remove the door from the trap door system by removing the two Allen screws that hold the door
Continued overleaf
17
Make the AC-M5 W MKII ready for use, continued Trap door system, Follow these steps to install the unit in the door trap system continued
Step 2
Action Loosen the 21 screws that hold the front grill. Dismount the front grill and the filter
3
Lift the unit to the location of the trapdoor by means of a forklift
4
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
5
Align the two M8 holes roughly with the big Ø25 mm holes in each horn when pushing in the ACU
Continued overleaf
18
Make the AC-M5 W MKII ready for use, continued Trap door system,
Step
Action
continued
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
Remount the filter, the front grill and the 17 screws. Do not remove the two M8 finger screws just yet
8
Mount the 2 draw out roller mechanisms (delivered separately in a small bag) as shown in the pictures in step 5 and 6
062367 • Version 1.0 • 14.02.2011
Continued overleaf
19
Make the AC-M5 W MKII ready for use, continued Trap door system, continued
20
Step
Action
9
Next mount the buffer consoles. One for each side
10
Connect power
11
Re-mount the door of the trap door system and shut it securely using the snap locks from the outside of the shelter
ACU removal Procedure
Follow this procedure to remove the ACU: Step
Action
1
Switch off the ACU and remove the power cable from the shelter connection
2
Ensure ACU is in the filter change/service position, with the securing knobs loosely fitted in the large holes in the horns
3
Unscrew the 19 torx 15 screws and detach the front grill of the unit
4
Remove the filter and the exhaust/discharge grill Do not harm the EMC seal in the front grill
5
Stowed away the power cable inside the ACU for convenience
6
Remove the flap from the door trap system by removing the two Allen screws that hold the door
7
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
9
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
10
Remount and securely close the flap of the door trap system with the snap catches on the outside of the shelter.
062367 • Version 1.0 • 14.02.2011
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
21
Starting up and shutting down the air conditioner Warning
Cycling the temperature dial up and down rapidly will cause the cooling circuit not to start. This is due to a start up delay of the compressor built in to the controller.
Before starting up Before starting the AC M5W, the unit has to be brought into the deployed position. Follow this procedure: Step
Action
1
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
2
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:
Fault
Step
Action
1
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.
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 20°C-60°C 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
Starting up and shutting down the air conditioner, continued Fault, continued
• Compressor thermo relay: Running current for the compressor is too high • OT thermostat (only in models with heating installed): High air temperature, or non-operating evaporator fan has stopped the heating coil Refer to the “Fault finding guide”, page 33 for possible solutions.
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
Release the two snap catches and unscrew the two hand screws, from their parking position and pull the unit back into the container
3
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.
4
Disconnect the power cable at the power supply and coil the cable if: • the air conditioner is put aside for a longer period or
062367 • Version 1.0 • 14.02.2011
• if service is to be performed
23
Transport and lifting of the unit Transport of the unit
The units are delivered, stacked and strapped to a pallet. Stack maximum 3 on a euro pallet. DO NOT STACK OTHERWISE
Lifting of the unit
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.
24
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
See page 26
Spare parts
29
Fault finding guide
33
Service agreement
35
062367 • Version 1.0 • 14.02.2011
Preventive maintenance
25
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.
Daily preventive maintenance
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
Action
1
Inspect the power cable for damage or loose connections
2
Inspect the air filter and remove any debris or foreign objects that may have accumulated on the filter Continued overleaf
26
Preventive maintenance, continued Monthly preventive maintenance
Please follow this procedure to do monthly preventive maintenance or every 200 hours of operation: Caution When dismounting the front cover you are breaking the EMC seal. When remounting the unit be aware that the EMC seal is intact and restored properly. Step
Action
1
Perform daily maintenance
2
Clean the air filter with a hoover or wash it in luke warm soap water. See the drawing below and follow the steps to get access to the filter
g
e
c
062367 • Version 1.0 • 14.02.2011
f
d
3
Loosen the two latches in each side of the unit c
4
Grab the handles d (one in each side) and pull the unit into the container
5
Fasten the screws e (one in each side) to fix the unit
6
Dismount the front frame by unscrewing 16 torx 21 screws f to get access to the filter
7
Grap the filter g behind the frame and clean it with a hoover or wash in luke warm soap water
8
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 h
h
9
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
27
Preventive maintenance, continued Annual preventive Follow this procedure to carry out the annual preventive maintenance: maintenance Caution When dismounting the front and the top cover you are breaking the EMC seal. When remounting the unit be aware that the EMC seal is intact and restored properly. Step
Action
1
Perform the daily and monthly maintenance, see above
2
Place the unit on a surface where the front frame can be free
3
Inspect the evaporator and condenser coils. See the drawing below and follow the following steps to make access to the coils:
d
e
c
28
4
Dismount the front frame by unscrewing 16 torx 20 screws c to get access to the filter
5
Dismount all 21 screws on the top cover d, top, sides and back
6
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 e
7
Clean the drip tray
8
Inspect and if necessary clean the radial wheels in the two fans
9
Follow the above steps just in reverse order to remount the unit
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.
062367 • Version 1.0 • 14.02.2011
Continued overleaf
29
Spare parts, continued Illustration
Available spare parts for the Spare parts:
Fig. 2 Continued overleaf
30
Spare parts, continued
062367 • Version 1.0 • 14.02.2011
List
List of spare parts for the Spare parts: Index No.
Part No.
Nomenclature
NATO No.
1
063108
Cover complete with insulation
1670-22-620-0246
2
063109
Evaporator coil
4130-22-620-0248
3
066668
Heating 2000 W complete
4520-22-620-0249
063111
Fan and fan housing complete, evaporator
4120-22-620-0312
4 5
063112
Fan, evaporator
4140-22-620-0250
6
063113
Drip tray with drain tube components
9999-22-620-0251
7
063114
Handle, set with 2 pcs.
5340-22-620-0253
8
063115
Grill, internal side
5340-22-620-0256
9
063116
Front gable, complete
5340-22-620-0255
10
063117
Filter
4130-22-620-0257
11
063118
Base plate, complete
1670-22-620-0259
063119
Fan and fan housing complete, condenser
4140-22-620-0261
12 13
063120
Fan, condenser
4140-22-620-0263
14
063121
Condenser coil
4130-22-620-0265
15
063122
Sensor, set with 2 pcs.
6685-22-620-0266
16
063123
Inspection glass
6680-22-620-0316
17
063124
Expansion valve
4820-22-620-0267
18
063125
Service valve
4820-22-620-0268
19
063126
Switch, high pressure
5930-22-620-0270
20
063127
Compressor
4130-22-620-0271
21
063128
Receiver
4130-22-620-0272
22
063129
Dry filter
4130-22-620-0273
23
063130
Control box complete
4130-22-620-0274
24
063131
Capacitor 5µF
5910-22-620-0275
25
063132
Capacitor 40µF
5910-22-620-0276
26
063133
Capacitor 2,5µF
5910-22-620-0277
27
063134
Front label, cable entry, switches and 5975-22-620-0278 potentiometer
28
063135
Control box bottom
6110-22-620-0279
29
063136
Rubber grommet set
5365-22-620-0280 Continued overleaf
31
Spare parts, continued List, continued
32
Index No.
Part No.
Nomenclature
NATO No.
30
063137
Control, printed circuit board
5998-22-620-0281
31
063138
Control box, cover
5340-22-620-0282
32
063139
Copper tube set
4710-22-620-0296
33
063140
EMC seal complete, 2 pcs.
4120-22-620-0311
Fault finding guide Fault finding
Malfunctions that might occur in the operation of the air conditioner are listed in the table below. Reference to actions required to restore the air conditioner to normal operating condition are also indicated. If the air conditioner should malfunction, find the problem in column 1. Columns 2 and 3 describe the possible causes and corrective actions. The list of problems, causes, and remedies will only give an indication of where a possible problem can be and what actions are needed to correct the problem. Problems, which are caused by electrical faults or related to the cooling plant, have to be corrected by skilled personnel Problem c
Cause d
Action e
The unit does not operate. The power indicator lamp on the control panel is not ON
No power input
Check that the power cable is correctly connected to power source and unit Check that power source is turned on and providing 1 × 230 V AC
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
Check the condenser side for sufficient air flow. Be sure that no air path is blocked The evaporator is blocked with ice. This will auto reset in time. Yellow light means the unit is operated inefficiently
Cooling circuit only operates a very short time before HP/LP pressure sensitive switch cut-out Power indicator lamp is green
Ambient temperature is not Wait until ambient temwithin working range 20 °C – perature is within working 60 °C range. Allow the unit to cool down (10-15 min.)
Cool light is green and turns yellow.
062367 • Version 1.0 • 14.02.2011
Air conditioner operates but no cooling. The power indicator lamp is green. Cooling lamp is red
Refrigerant leak. Call an air condition serInternal temperature protec- vice technician tion compressor has cut-out. Faulty compressor
Continued overleaf
33
Fault finding guide, continued Fault finding, con-
Problem c
Cause d
Action e
tinued
No heating action possible. Power light is green.
Overheat thermostat failure or loose electrical connection
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
Check for blocked fan(s). Check for loose connectors
Heat indicator lamp is red.
Fans stop running. Fan light is red
34
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
• Phone no.
• Site/location (unit)
• Company
• Email
• Serial no/order no.
• Country
• Type (unit)
• 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:
[email protected]
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.
Corrective and emergency repair
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/S’s.
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
062367 • Version 1.0 • 14.02.2011
Phone: +45 9614 4767 Mobile: +45 2399 4066 Email:
[email protected]
35
Technical information Overview Contents
This section covers the following topics: Topic
36
See page
Technical data
37
Dimensions
38
Wiring diagram
39
References for the wiring diagram
41
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)
Value 230 V 1 PH/50 Hz 2.4 kW/11.2 A 4.7 kW 2.0 kW/8.6 A
Airflow low, evaporator
420 m³/h
Airflow high, evaporator
900 m³/h
Airflow, condenser Refrigerant/Load Max. refrigerant pressure Operation temp. range
1475 m³/h R134a/1.4 kg 28 Bar 20-60 °C
Weight Noise level (1 m) low speed Noise level (1 m) high speed
49/48 dB(A) *)
64/63.5 dB(A)
With/without compressor active
062367 • Version 1.0 • 14.02.2011
*)
79 kg *)
37
Dimensions Illustration
38
This illustrates the unit dimensions (mm):
Wiring diagram
062367 • Version 1.0 • 14.02.2011
Wiring diagram, a
This is the wiring diagram for the unit, references are available on page 41:
Continued overleaf
39
Wiring diagram, continued Wiring diagram, b
40
References for the wiring diagram References
The references refer to the wiring diagram: Reference E1
Electrical heat 2x1000 W/230 V
M1
Compressor ZR 22 K3E-PFJ
R1
RC unit 470n + 47R X2
C1
Capacitor for compressor 40 MF/400 V
M2
Condenser fan EBM A4E350
C2
Capacitor for condenser fan
M3
Condensate pump Blue Diamond
C4
Capacitor for evaporator fan 5mF/450 V low speed
M4
Evaporator fan EBM R4E280
C3
Capacitor for evaporator fan 2,5 mF/450 V
R2
Limit air temperature sensor heat/fan
R3
Return air temperature sensor
S1
Test button (only for service)
B2
High pressure switch with auto reset
S2
Fan speed selector high-low
S3
Temperature set point
S4
Function selector Auto-Off-Fan
*)
Option
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*)
Description
41
