Dantherm VAM 40 Army Heater Service Manual VA-M 40 MK II_ServiceM_2.2_en_971145_92s

VA-M40 MKII Service manual Rev. 2.2

971145 • Version 2.1 • 22.10.2012

en

1

Der tages forbehold for trykfejl og ændringer Dantherm can accept no responsibility for possible errors and changes

2

Irrtümer und Änderungen vorbehalten Dantherm n’assume aucune responsabilité pour erreurs et modifications éventuelles

Introduction Overview Introduction

This Dantherm portable heater has been designed and manufactured with high quality materials and care in workmanship. The instructions in this service manual have been prepared to ensure that, when followed, this portable heater will provide long and efficient service. This is the service manual for the Dantherm VA-M40 MK II unit.

Models

This manual covers for the following models: Dantherm number 322017

Warning

Code VA-M40-B-225-RXXXX

NATO stock number -

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. Heaters should only be operated by qualified (trained) personnel. Failure to do so can result in personal injury or equipment damage. Read the entire manual before the initial start-up of the heater. It is important to know the correct operating procedures for the heater and all safety precautions to prevent the possibility of property damage and/or personal injury.

Contents

This manual covers the following main topics: Topic Introduction

See page 3 4

General information

7

Syntax

8

Product description

9

User’s guide

20

Service guide

34

Technical information

82

Index

87

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Safety and warning instructions

3

Safety and warning instructions Introduction

Safety must always be the operator's prime concern. The operator must read and understand this manual and all safety signs on the heater before operating the equipment. Failure to follow these safety precautions could result in property damage and/or personal injury or death. This safety summary describes basic safety measures, which apply to the use and maintenance of the equipment. Further safety measures are described in other sections throughout this Manual.

Definitions

The following safety alert symbols are used throughout this manual: Danger

Indicates immediate hazards which WILL result in severe personal injury

or death Warning

Indicates hazards or unsafe practices which COULD result in severe per-

sonal injury or death Caution

Indicates hazards or unsafe practices which COULD result in minor per-

sonal injury or equipment damage Note

Indicates special features or operation of the heater

Caution

Follow all rules of safety and safe operation.

Danger

The heater must be earthed while in use to protect the operator from electrical shock. The heater is supplied with a three-core cable and three-pin earthed plug to fit correctly earthed sockets. The green (or green/yellow) core in the cable is the earthing wire. Never connect the green (or green/yellow) wire to a live terminal.

Danger

Always disconnect the power cable from the electrical source when not in use, before servicing and when changing accessories.

Danger

Use only commercial Diesel (Dieso) or the following NATO, US and civilian designations: F34 (AVTUR (FSII)) or JP-8 or JET A-1 (b), F35 (AVTUR) or JET A-1, F44 (AVCAT) or JP5 or TURBO 5, F54 (Dieso), & F58 (KeroB). Do not use petrol/civgas/gasoline as it may cause a fire and an explosion.

Danger

Observe all standard fuel handling precautions when handling fuel. Avoid spilling fuel on or near the heater to prevent possible fire. Always stop the heater when changing the oil lance from one drum/jerry can to another.

Danger

Do not park vehicles, engine driven generators or other equipment which produce toxic or noxious fumes near the heater. These exhausts could be drawn into the fresh air intake of the heater. Avoid operating the heater in a location near objects which could cause down drafts. Flue gases from the heater stack could be forced downward into the fresh air intakes.

Warning

Never operate the heater in the shelter to be heated. The heater is designed for placement in outside (open air) installations using flexible ducts to connect the heater to the shelter or other enclosed spaces. Continued overleaf

4

Safety and warning instructions, continued Warning

If, at any time, exhaust fumes or fuel odours can be detected in the space being heated or ventilated, shut the heater down immediately. If an external source of the fumes cannot be detected and eliminated the heater combustion chamber must be inspected for cracks or other defects.

Warning,

Electrical shock

electrical hazards

This heater, and its associated thermostat, operates at 1 × 230 V AC; 50 Hz and consequently there is a risk of electrical shock. Electrical safety precautions are to be strictly observed. Always disconnect the power supply from the heater unit prior to servicing or movement. Ensure that regular checks for damage to cables and connectors of both the electrical supply and the thermostat are carried out; any damage found must be rectified immediately. Earthing This heater must be earthed through the 3-core electrical supply cable.

Warning

Handling of fuel

handling and use

Fuel is a hazardous substance. Refueling operations must take place in well ventilated

of fuel

areas, away from sources of ignition. Refer to relevant safety data sheetsand COSHH assessments. Avoid any spillage of fuel. Wherever possible use a drip tray under the heater. Use of fuel Before and during use of the heater ensure that all fuel lines/hoses are secure and leak proof. When connecting the fuel lance to the fuel tank/jerry can or 205 l drum ensure that it is secured into place in the fuel container and avoid any spillage of fuel on or near the heater. Stop the heater when changing fuel lances between one fuel drum and another. When the heater is not in use for any extended period, or during transportation, ensure that the fuel lance is disconnected from the fuel supply hose and both are securely stowed in the housing. In such circumstances ensure that the cap of the fuel container is securely closed. Avoid the build up of water in the bottom of fuel supply containers. Risk of fire Ensure that the burner unit is correctly located into its operational housing and the locking bar is applied before use. Ensure that any fuel spillages are mopped up and absorbent material disposed of. Do not let hot heater surfaces come into contact with items which could readily ignite.

971145 • Version 2.1 • 22.10.2012

Continued overleaf

5

Safety and warning instructions, continued Warning

Location

location and ex-

Never operate the heater in a confined space without adequate ventilation. The heater

haust fumes

should be located externally, and the heat transferred to the shelter by the insulated flexible ducts. The location of the heater should avoid any possibility of ingesting exhaust fumes from other sources such as vehicles, generators or other engines. Any local downdrafts of air with associated fumes should be avoided. Fumes Should at any time personnel in the heated shelter experience fuel odour or fumes the heater is to be shut down and the source investigated. If the source of the fumes cannot be detected and eliminated the heater must be changed and the defective heater inspected for combustion chamber cracks or other defects responsible for the fumes. Obstruction of air intakes and ducts Ensure that all air intakes/ducts, and where fitted, exit ducts are totally free from the ingress of vermin or debris. Take corrective action to clean/remove obstructions on a regular basis.

Warning,

Lifting and movement

physical handling

The weight of the heater is shown in the specifications, page 83 and is beyond the safe handling of one person. Lifting and/or movement should be either undertaken by Mechanical Handling Equipment (MHE) or by sufficient numbers of personnel correctly located around the heater so as to avoid injury or strain. When lifting the handrails are to be used.

Caution

If the heater has been stored for an extended period the heater should be run for 5 minutes before connecting the air ducts.

Caution

6

Do not disconnect the power until the air supply fan has completely stopped.

General information Introduction

This manual contains instructions for the operation and maintenance of 38 kW heater model VA-M40 MK II, oil fired, portable, duct type, as manufactured by Dantherm.

Target group

The target groups for this service manual are the:  User of the heater  Technician who maintains the heater

Copyright

Copying of this service manual, or part of it, is forbidden without prior written permission from Dantherm.

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.

Part number

The part number under which this service manual can be ordered is 971145.

EC-Declaration of

Dantherm, Marienlystvej 65, DK-7800 Skive hereby declares that the:

Conformity

VA-M 40 MK II, product no. 322017 is in conformity with the following directives: 98/37/EEC

Directive on the safety of machines

73/23/EEC

Low Voltage Directive

89/336/EEC

EMC Directive

is manufactured in conformity with the following harmonized standard EN 292

Machine Safety

EN 60 335-1 Low Voltage EN 61 000-1 Immunity EN 61 000-3 Emission EN 13 842

Oil fired forced connection air heater

Skive, 17.06.2005 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 pro-

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tect the environment.

7

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-X1

AC

Air Conditioner

VA

Heater (diesel)

M

Military unit

5

5 kW nominal performance

W

Window mount

S

Split unit

H

heat option

070

7000W heat

A

1 ph; 115 V AC; 60 Hz

B

1 ph; 230 V AC; 50 Hz

C

1 ph; 230 V AC; 60 Hz

D

3 ph; 230 V AC; 60 Hz

E

3 ph; 460 V AC; 60 Hz

F

3 ph; 400 V AC; 50 Hz

225

225 mm duct connection

315

315 mm duct connection

R6014

X

8

Four digit RAL colour code

Specifics/custom

Product description Overview Introduction

This section will give a more detailed description of the VA-M40 MK II and its functionality. The space heater can be split up into five basic systems, see the below topics for further information.

Contents

This section covers the following topics: Topic

See page 10

Cabinet

11

Combustion system

13

Air circulation system

14

Fuel system

15

Control system

16

Accessories

19

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General description

9

General description Purpose and field

The Dantherm portable, duct type, heater model VA-M40 MK II is designed primarily to

applications

supply un-contaminated, heated air to tents and other types of temporary or portable shelters. In addition, the heater is suitable for various field applications such as the warming up of cold soaked equipment, engines, vehicles, aircraft, and other spot or space heating requirements.

Principle

The heater operates on the indirect fired (clean air) principle thus ensuring that no combustion products or fumes are introduced into the occupied spaces. The forced air system provides the most rapid of warm-up capabilities. The units are essentially selfcontained requiring only a source of external electric power.

Performance char-

The heater has a maximum heat output of 38 kW with a minimum combustion efficiency

acteristics

of 85 %. The unit will start at temperatures as low as - 40 °C, and is factory set for operation to an altitude of 1,500 m Operation at higher altitudes requires minor field adjustment of the oil burner. The protective cabinet allows operation in snow or rainy conditions.

Set up and opera-

Set up and operation can be done by a single person. After start up, the heater functions

tion

are automatic, thus permitting the item to be left unattended between periods of refueling. An optional remote thermostat may be connected to the heater for accurate temperature control within a tent or other enclosure type. The control system also includes a "vent" only position, which can be used to bring in fresh air, or circulate interior air, even when heating is not required. The item is designed to be suitable for all standard transportation modes.

Replacement of

All critical sub-systems and component assemblies are replaceable as modular kits; this

parts

ensures a repair capability at Unit level. No special tools are required for module replacement.

Standard configuration

The following is the standard configuration:  Heater VA-M40 MK II  Insulated flue stack  Oil lance for 205 l d6rum  Service manual  2 wheels with rubber tires

10

Cabinet Cabinet

The steel cabinet completely encloses the space heater components and systems. The powder painting finish is standard NATO green, RAL 6014.

Illustration

This illustrates the heater:  1 1 

 





No. 

Part Outlet openings



Flue stack



Access holes for wheel storage Storage compartment



Flue outlet opening



Adjustable fresh air openings



 

  Fig. 1

Wheels





Wheels



Skids



Parking stand



Hinged door 1 1

Inlet openings

The two wheels  can be stored on top of the heater with the short axles placed into access holes  or the storage compartment . The wheels can be removed or refitted by a single person, no tools are required. The parking stand  can be fixed in a horizontal position when the wheels are removed.

Lifting and carry-

Manual lifting and transporting the unit is carried out by the use of the side handrails,

ing

which are also suitable for the tie-down anchor points. Slots in the skid runners allow it to be handled by a forklift truck. We have a lifting point in the flue gas outlet, which makes it possible to lift the heater by a crane.

Skid runners

The base of the cabinet is fitted with skids , so that the heater can slide over ice, snow or earth with the wheels removed.

Storage compart-

When not in use, the remote thermostat (accessory), CO monitor (accessory), tool kit,

ment

service manual, and wheels are stored within the storage compartment  at the rear of

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the heater. Burner compart-

The hinged door  at the front of the unit gives complete access to the burner com-

ment, service ac-

partment which houses the oil burner, electrical controls, fuel systems and filter.

cess

At the same time it is the storage room for the power supply cable under transport. Continued overleaf

11

Cabinet, continued Duct openings

The air outlet openings  can be closed, when not in use, by covers secured with rubber straps, which are designed to be operated by personnel wearing protective gloves. Duct connections are provided for two tents, both supply and return air, making the heater suitable for either heating 100 % outside fresh air, or recirculating interior air. (Recirculation can significantly reduce fuel consumption).

Fresh air openings

On both sides of the unit are adjustable fresh air openings  allowing a variable amount of fresh air to be utilised, when recirculation ducts are mounted.

Flue outlet open-

The flue outlet opening  can be closed by a cover, when not in use which is designed

ings

to be operated by personnel wearing protective gloves. The flue stack  is fitted with insulated handles for easy and safe fitting and dismantling. For transportation and storage purposes the flue stack is placed on brackets along the cabinet side.

12

Combustion system Introduction

This system consists of an oil burner , combustion chamber with heat exchanger , and the flue stack .

Illustration

This illustrates the combustion system:



No. 

Part Flue stack



Heat exchanger



Inspection glass



Oil burner

*

  

Fig. 2 Combustion sys-

This system consists of an oil burner , combustion chamber with heat exchanger ,

tem

and the flue stack . The oil burner includes an electrically driven combustion air fan and a fuel pump, which delivers diesel fuel to the nozzle where it is atomized. A certain mixture rate of combustion air and atomized fuel will create a sort of gas which gives high efficiency combustion without soot. An electric transformer supplies high voltage for ignition across two electrodes upon start up. When the flame is established the ignition ceases. The operation cycle is controlled by a solid-state electronic device. During start up a 15 second pre-purge is followed by the opening of the solenoid valve for oil atomizing and ignition. Safety shutdown will occur after five seconds if a flame is not detected via the photo cell unit. The burner flame is confined within a combustion chamber and heat exchanger of

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sealed construction which prevents the combustion gases from escaping into the air circulation system. The flame can be inspected through a small glass window  in the warm air discharge compartment. An insulated flue stack is extended to discharge the exhaust gases upwards approximately 2 m above ground.

13

Air circulation system Illustration

This illustrates the air circulation system:



No. 

Part Heated air outlet



Direct driven fan



Air inlet



Fresh air intake







Fig. 3 Air circulation sys-

The air circulation system consists of a direct driven fan  and internal air passages

tem

from the air inlet  to the heated air outlet . The space heater can operate as a totally external (fresh) air heater or in a recirculation mode utilising most of the air from the heated space. In recirculation mode it is possible to run with up to 476 m3/h fresh air by opening the round fresh air intake  on the side of the unit. Four air duct connections are provided, two on the supply discharge side  and two on the inlet/return airside . The connectors are compatible with male spigots/connectors for 225 mm flexible ducts which are fastened with rubber latches.

14

Fuel system Illustration

This illustrates the fuel system: 

No. 

Fuel pump



Flow control/DeAerator





Part



Fuel pre-heater



Filter/water separator



Oil lance





Fig. 4 Fuel system

Fuel is sourced externally from either a drum or jerry can, and is drawn by the burner pump to the burner through a fuel assembly starting with oil lance  for drum or a shorter type for jerry can (standard). In the fuel line a filter/water separator  with a wire mesh is built-in to pick up debris and a glass receiver for collecting any small amounts of water. A flow control  operates as an air bleed receptacle and a regulator to establish a constant flow in a loop between the pump , the pre-heater  and the flow control . A fuel pre-heater  heats up the fuel to 50 °C before releasing it to the fuel pump. The pre-heater is provided with an automatically, integral thermostatic temperature control. In the pump , the fuel is sucked through a fuel filter which collects fine particles of dirt and foreign objects, which has not been taken out by the first filter in the water separator. The pump has an internal by-pass to lead part of the flow back into the preheater and flow control. The pump pressure can easily be adjusted and a gauge displays the true pressure. From the pump fuel travels to the nozzle through the fuel pressure tube. The nozzle

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contains the last fine filter in this system.

15

Control system Control system

The heater incorporates a control system that allows fully automatic operation after a start cycle has been initiated by the room thermostat. Safety devices will completely shut down ignition, fuel flow and fans in case of malfunction. All operating controls and components are mounted to permit easy access for operation, maintenance and troubleshooting. Details about how to operate the unit is to be found in section “Operation of the heater”, page 27.

Illustration, outside This illustrates the control panel which is placed on the left hand side of the unit when standing in front of the burner compartment:





No. 

Connector for remote thermostat



Connector for CO monitoring



Function switch



Part

See details on the different positions in section “Operation of the heater”, page 27 

Power supply cable



Fig. 5 Illustration, inside

This illustrates the control panel which it is possible to see on the left hand side, after opening the burner compartment cover: No. 



Part LED lights which indicate the different states of the unit. These are explained in section “Operation of the heater”, page 27



Hour-meter which accumulate the hours the burner is active





Reset button for circuit breaker which protects the control printed circuit board

 Fig. 6

Continued overleaf

16

Control system, continued Room thermostat

The room thermostat (accessory) will be placed inside the tent, to control the room temperature. The wanted temperature will be set on the thermostat. If the temperature falls below the set point the thermostat will automatically start up the burner. After reaching the set point the thermostat automatically shuts off the burner of the unit again. See also “Set-up”, page 23 (Thermostat) for further explanation.

CO monitor

The CO monitor (accessory) will be placed inside the tent nearby the warm air distribution duct. The CO monitor is factory set and will stop the complete unit if the CO content in the air is higher than the set point of the monitor. At the same time the monitor will give an acoustical signal. See also “Set-up”, page 23 (CO-monitor) for further explanation.

Internal fan/limit

The internal fan thermostat control delays fan operation until the discharge air tem-

thermostat

perature has reached the preset factory temperature of 60 °C. This means that the fan will not operate after burner start before the heat exchanger is heated to this temperature. After the burner stopped the fan will continue to operate and cool the heat exchanger/combustion chamber until the air discharge temperature has fallen to approximately 30 °C. The limit thermostat automatically stops the burner if the air discharge temperature exceeds 80 °C. The fan will continue. When the temperature has fallen by approximately 5 °C, then the burner will automatically switch on again.

Overheat protec-

The overheat thermostat operates when the heat exchanger is in danger of being dam-

tion

aged from an excess of temperature. This thermostat protector shuts down the fuel, ignition and air supply systems. The red OT indicator lamp on the internal control box illuminates. Follow this procedure to reset the system (after determining the fault):

Burner flameout

A flameout protector built in into the burner, activates when the burner flame is abnor-

protection

mal or unstable. This safety device automatically shuts off the fuel flow, ignition and combustion air supply. The red reset button on the burner control box illuminates.

LED lights

There are four LED lights on the inside control panel which are indicating the state of the unit:

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LED

Color

Indication

CO override

Yellow

Illuminates if no CO monitor is connected

OT failure

Red

Illuminates if the sensor in the heat exchanger registers a temperature higher than the set point for this sensor. In this case the unit will stop totally and can only be started again after having pressed the reset button on the OT thermostat Continued overleaf

17

Control system, continued , continued

LED CO failure

Color Red

Indication Illuminates when a CO monitor is connected and a CO alarm has been detected. In this case the unit will stop totally and can only be started again after having pressed the reset button on the external CO monitor

Power

18

Green

Illuminates when the power is connected to the unit

Reset circuit

For protection of control circuit this breaker is installed. If it trips off, the breaker has to

breaker

be reset by pressing the button.

Hour meter

This hour meter accumulates the hours the burner is active.

Accessories Introduction

There are different accessories available for the VA-M40 MK II which can be ordered directly from Dantherm. You will find the part number or NSN for ordering in the spare part section on page 58.

Accessories

List of the available accessories: Illustration

Description

Illustration

Description

Storage bag for

Remote thermo-

insulated air duct

stat

Insulated air duct

CO monitor

3m

Air distribution

Dry powder ex-

duct 5 m

tinguisher

Jerry can

Oil lance for jerry

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can

19

User’s guide Overview Introduction

This section will give a more detailed description about how to utilize the heater. The section contains all the necessary information which is needed to install, start up, run and store the unit.

Contents

This section contains the following topics: Topic

20

See page

Pre-planning

21

Set-up

23

Operation of the heater

27

Fuel handling

30

Operation at high altitudes

31

Shutdown of the heater

32

Transport and storage

33

Pre-planning Introduction

The set up is an important factor for gaining the highest performance and reliability from the warm air heaters with a minimal power and fuel consumption. A camp application can be set up in various ways and still work, but a few important tips will be given in this section. The normal set up for a VA-M40 MK II has been designed for two tents with a set of return and supply air ducts for each tent. Be aware it is not advisable to connect a toilet nor kitchen/mess tent to personnel or operational tents/shelters.

Illustration

This illustrates the normal setup for VA-M40 MK II units: Return air ducts

Supply air ducts Fig. 7 Location

It is important that the VA-M40 MK II units are always placed outside the tent with the flue stack mounted, to avoid smoke gases from being drawn into the tent, or into the fresh air intake of the unit. In planning the best arrangement for air distribution to tents or other enclosures, determine the best location for the heater within 1 to 2 m of the space to be heated, and access to an approved power source. The space heater requires 1 × 230 V AC; 50 Hz. Allow space around the heater for operating and servicing accessibility. If possible, keep unit away from areas of dried grass or leaves which present a fire hazard, particularly from spilled fuel, or possible fuel leaks from external fuel hose connections or internal fuel leaks.

Warning

Do not operate the space heater in a location where down drafts or wind currents can force flue stack exhaust gas down to the heater intake duct. Do not park vehicles



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where exhaust gases can be drawn into the heater intake.

Fig. 8 Continued overleaf

21

Pre-planning, continued Duct connection

If the VA-M40 MK II is used to only warm up one tent, try to use both in and outlet connections of the unit. Be aware that blocking one of the inlet and outlet duct connections on the warm air heater will result in very high exhaust air temperature. For that reason the burner will be very often shut down by the internal safety thermostat and not any longer controlled by the room thermostat inside the tent.



 Fig. 9

Air recirculation

In order to get the best efficiency out of the heaters it is important always to use the return air duct when connecting the VAM unit to the tent, as the room temperature normally is higher than the ambient outside temperature. This will save fuel and warm up the tent quicker. In cases where air recirculation from the tent is not appropriated, it is possible to run the heater without return air ducts. Please be aware of the dust risk and generation of over pressure in the tent when running with total fresh air.

22

Set-up Illustration

This illustrates the unit: 

No. 

Part Parking stand



Locking handle



Fresh air opening



Flue stack





 Fig. 10 Installing the unit

Follow this procedure to make the unit ready for running: Step 1

Action Decide if the unit should run with the wheels in place, or without. Dantherm suggests that if you are using the unit for a longer period to remove the wheels and store them in the storage compartment. To remove the wheels:  Fold up the parking stand  by pushing the stand first downwards and then lift it up into parking position  Pull the locking handle   Remove the wheel

2

Remove the flue stack  from the brackets along the side of the heater and install the flue stack into the flue flange after removing the cover

3

Set the function switch on the outside control panel to O. Uncoil and route the power cable in the direction of the power source. Calculate the distance from the heater location to the power source to assure you have sufficient power cable. Do not deploy power cable until step 6

4

Install the room thermostat and CO monitor (accessories) inside the tent (see also separate description), uncoil and route the cables to the unit and connect

971145 • Version 2.1 • 22.10.2012

the thermostat and CO monitor female connectors to the heaters outside male 5

Open the two fresh air openings  at the side of the unit if there is a need for fresh air

6

Verify that the fuel is approved for the intended use. Take the fuel lance out of the storage compartment and connect it with the fuel hose and connect it to a compatible jerry can or fuel drum. The unit is now ready for operation. Continued overleaf

23

Set-up, continued Danger

Avoid spilling fuel on or near the heater. Protect the fuel hose and fuel containers by keeping them out of traffic areas. Observe all directives for fuel handling and fire prevention. Use only approved diesel or jet fuel. Do not use petrol/civil gas/gasoline as it may cause a fire and an explosion!

Insulated air ducts

The insulated ducts should be as short as possible to avoid a high pressure loss in the system (and therewith a reduced air volume) plus transmission losses to the cooled ambient air. The ideal length for the ducts is 6 m for each air circuit or tent. The maximum combined length of air ducts is 9 m. The use of both openings is required at all times. As the ducts will introduce a pressure loss every time there is a bend it is important that the duct is as straight as possible. Small degree bends are not as crucial as large degree bends are (sharp bends > 90 deg.).

Procedure

Follow this procedure to connect the ducts: Step 1

Action Remove the two front covers from the air discharge opening by loosening the rubber straps

2

Connect the male connector/spigot on the ducts to the discharge openings and securely engage with the rubber straps

3

Insert the end of both supply ducts into the shelter boots

4

Connect the female connector/spigot on the second set of ducts to the inlet openings at the end of the unit and securely engage with the rubber strap

5

Insert the end of both return air ducts into the shelter boots

Air distribution

For the best distribution of the warm air inside

duct

the tent use an air distribution duct placed on the floor. This will give the best heat distribution, as warm air always moves upwards. Be aware that the openings of the duct are not

Air in

blocked, so the warm air can be distributed without any disturbance. The air distribution duct can be directly connected to the insulated air discharge duct. The return air back to the VAM unit is drawn through the opening of the return air duct.

Fig. 11 Continued overleaf

24

Set-up, continued Thermostat, illus-

This illustrates the remote thermostat:

tration  



No. 

Part Temperature knob



Set point scale



Connector



Thermostat cable

 Fig. 12 Procedure

When the unit operates on auto mode with the thermostat connected, the thermostat location is important. Place the thermostat inside the tent at the desired location according to this procedure: Step 1

Action Place the thermostat inside the shelter at the desired location. Avoid the direct hot air discharge from the heater ducts. Optimum control can be obtained by placing the thermostat at a height of 1.5 m and in a location near the return air end of the shelter Fig. 13

2

Set the desired temperature by rotating the knob , until the set point is displayed on the scale 

3

Route the thermostat cable  out of the shelter to the heater

4

Connect the cable assembly to the small compatible connector  receptacle located to the left of the function switch

971145 • Version 2.1 • 22.10.2012

Continued overleaf

25

Set-up, continued CO-monitor, illus-

This illustrates the CO (Carbon monoxide) monitor:

tration Part 

Function Red alarm lamp



Test and reset button



Green power on lamp



Connector



Monitor cable



 

 

Procedure

When the unit is running with the CO monitor connected, the monitor location is important. Place the CO monitor inside the tent at the desired location according to this procedure: Step 1

Action Place the CO monitor inside the tent near the air distribution duct and route the cable out of the shelter to the heater

2

Test the CO monitor by pressing the test button 2. The monitor should now give an acoustical signal. No further settings are necessary as the CO monitor works fully automatically

26

Operation of the heater Introduction

With set-up completed the heater is now ready for operation. The function switch position on the left side at the supply end of the heater contains all of the controls required for normal operation of the heater.

Reference

Please refer to section ”Control system”, page 16 to locate the functions, mentioned in the following.

Starting up

Before starting the unit up, verify that the switch is set at 0 (OFF). Turn the power on. Now the green lamp on the internal control panel will illuminate.

0 AUTO

VENT

MAN

Function switch Fig. 14 Function switch

With the remote thermostat connected and the switch turned to AUTO position, the

AUTO

heater will automatically maintain the temperature determined by the remote thermostat in the space to be heated. The circulation fan runs at the same time as the burner, but with thermostatic delayed start and stop through the fan thermostat.

Function switch

In the MAN switch position the heater operates continuously, regardless of a remote

MAN

thermostat. The operation will automatically be overridden by the limit thermostat function. If the air temperature exceeds 80 °C the circulation fan operates continuously.

Function switch

With the switch turned to VENT, the heater functions as a ventilation unit with the circu-

VENT

lation fan running continuously. The burner does not operate, unless a remote thermostat is connected, and the actual room temperature is lower than the thermostat settings.

Function switch

When the switch is turned to 0 (OFF) position, the burner stops. The fan continues to

0

run until the air outlet temperature of the heater has dropped to below 30 °C.

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Continued overleaf

27

Operation of the heater, continued Remote thermostat

This table gives an overview of the different reactions of the heater under specific con-

operation

ditions: Condition Room

Less than

tempera-

set thermostat

ture

value

Reaction  The burner fan will start ventilating the combustion chamber to make sure that no explosive gasses are left before starting the ignition  After approx. 15 seconds (pre-purge) the ignition circuit will energize and the solenoid valve will open the fuel supply and the combustion process starts  The flame can be inspected through the inspection glass on the combustion chamber, if one of the hoses on the discharge end is removed from the heater

Internal

More than

tempera-

35 °C

ture in the

 The fan will activate automatically by the fan thermostat  The heater will now run until the desired space tem-

heater

perature has been reached

Room

More than

 The remote thermostat will switch off the burner

tempera-

set thermostat

 The fan will continue to run until the temperature in-

ture

value

side the heater has dropped to approx. 30 °C and then stop

No flame

More than 5 sec.

 The burner primary control will shut off the electrical supply to the burner motor, ignition and solenoid valve  The red indicator lamp on the burner primary control will illuminate indicating a fault To reset the burner depress the indicator button on the burner control. See “Fuel handling”, page 30

Heater

More than

outlet

80 °C

 The burner will be stopped by the internal limitthermostat.

temperature

When the temperature has fallen approximately 5 °C the burner will automatically restart

Heater

More than

outlet

100 °C

temperature

 The OT (Overheat Temperature) thermostat will switch off the burner and fan.  The red indicator lamp on the inside control panel will illuminate The unit has to be reset manually on the OT thermostat Continued overleaf

28

Operation of the heater, continued Reset, CO monitor

When the CO monitor has given an acoustical alarm, caused by a too high content of the carbon monoxide inside the tent, the VA-M unit will stop. Follow this procedure to reset the CO monitor: Step

Action

1

Leave the tent immediately (everyone)

2

Ventilate the tent by opening all doors and windows

3

Find out what caused the alarm. Most likely it will be an engine running nearby the heater, with exhaust gases entering the heater through the fresh air opening

4

Restart the VA-M by pressing the reset button on the CO monitor

Reset, circuit

If there is an electrical fault the circuit breaker will stop the unit from running. In this

breaker

case you can see a white ring clearly on the reset button. To find out the reason for the fault and how to repair it see “Corrective maintenance”, page 39. Press the reset button to start up the unit again.

Reset overheat

The overheat thermostat operates when the heat exchanger is in danger of being dam-

(OT) protection

aged from an excess of temperature. This thermostat protector shuts down the fuel, ignition and air supply systems. The red OT indicator lamp on the internal control box illuminates. Follow this procedure to reset the system (after determining the fault): Step

Action

1

Turn the function switch to OFF

2

Reset the button on the overheat protection thermostat, after the system has cooled down

3

Reset, burner

Restart the unit by turning the function switch to AUTO again

A flameout protector built in into the burner, activates when the burner flame is abnormal or unstable. This safety device automatically shuts off the fuel flow, ignition and combustion air supply. The red reset button on the burner control box illuminates. The fault will be in most cases just missing fuel (see also “Fuel handling”, page 30). If this is not the cause refer to “Corrective maintenance”, page 39.

971145 • Version 2.1 • 22.10.2012

Press the red reset button on the control box to reset the burner. Daily inspection

The unit has to be inspected on a daily basis. Please see section ”Daily maintenance”, page 36 in the service section for further details.

29

Fuel handling Danger

Use only commercial Diesel (Dieso) or the following NATO, US and civilian designations: F34 (AVTUR (FSII)) or JP-8 or JET A-1 (b), F35 (AVTUR) or JET A-1, F44 (AVCAT) or JP5 or TURBO 5, F54 (Dieso), & F58 (KeroB). Do not use petrol/civgas/gasoline as it may cause a fire and an explosion.

Note

It is preferable to monitor the fuel supply and refill or replace the fuel supply before the heater stops.

Fuel starvation

When running low on fuel, an unstable flow occurs and the automatic burner primary

symptoms

control will shut down the burner. The red indicator light on the primary control panel will illuminate to indicate a flame fault condition and the oil burner will stop.

Refuel and restart

To refuel and restart the heater after a fuel starvation fault, use the following procedure: Step

Action

1

Turn the function switch to 0 (OFF) position

2

Remove the fuel container adaptor from the empty container and insert into a replenished jerry can or drum

3

Reset the burner primary control to restart the heater after a fuel starva-

Burner reset button

tion shut down. Open the burner compartment cover and activate the reset by depressing the button once. The heater may then be activated by selecting the desired position of the function switch. If the fuel line contains too much air the burner may not operate on the first attempt. Wait a short while and depress the button again, if it is illuminated.

30

Fig. 15

Operation at high altitudes Introduction

The burner setting from the factory will normally be sufficient up to 1,500 m above sea level. When used in areas at higher altitude the heater might start to produce soot due to insufficient oxygen for the combustion. In this instance dark grey or black exhaust will be emitted from the flue pipe some adjustments have to be made. As the combustion airflow is adjusted nearer to its maximum, a smaller nozzle of the standard 0.85 US Gal/h size will be required. These can be enquired from Dantherm. Additionally the air damper adjustment has to be increased to 10.0 and the combustion head to 2.1, Refer to “Burner adjustment”, page 53. At even higher altitudes the oil pressure should be gradually reduced to between 810 bar.

Caution

Changing the burner nozzle and making changes to the combustion adjustment is a

971145 • Version 2.1 • 22.10.2012

task only for the responsible maintenance personnel!

31

Shutdown of the heater Shutdown

To shutdown the heater system from any mode of operation turn the function switch to 0 (OFF). The burner will shut off, but the fan will continue running for one to two minutes until the internal heater

0 AUTO

VENT

temperature has dropped below 30 °C. MAN

Fig. 16 Warning

Never disconnect the power supply cable from the power source, before the heater has cooled down completely! This can damage the combustion chamber or heat exchanger!

Total shutdown

If the heater has to be moved, continue the shutdown as follows: Step 1

Action Perform the shutdown as described above before proceeding with the total shutdown

2

Disconnect the power supply. Coil and stow the power cable in the burner compartment

3

Disconnect the remote thermostat, if used, at the heater and replace with the dust cap on the thermostat connector. Stow the thermostat with cable in the storage compartment

4

Disconnect the CO monitor, if used, at the heater and replace with the dust cap on the connector. Stow the monitor with cable in the storage compartment

5

Disconnect the air ducts. Stow the ducts in the compression sacks as required and close the two outlet openings with the covers

6

Remove the fuel lance from the fuel source and stow it in the storage compartment

7

Dismantle the flue stack and stow it along the cabinet side on the brackets

8

Both wheels can be removed by lifting at the handle and at the same time pulling the wheels out in a horizontal direction, if the heater has to be transported by a vehicle or moved upon snow. The wheels can be stowed on top with the short axles placed into access holes behind the removable covers, or stored in the storage compartment. The parking stand in front has to be pushed down and lifted and secured in a horizontal position. This completes the shutdown and the unit is now ready for transportation

32

Transport and storage Manual movement

With the help of the two wheels and the front handle the unit can be moved by one per-

and lifting

son over a short distance. Before moving the unit the front stabilizer should be fixed in a horizontal position. If it is not possible to use the wheels because of sand, snow or uneven ground the unit is provided with handrails on each side of the cabinet for lift and moving the heater with four persons and positioning it.

Warning

The weight of this heater is shown in the specifications, which is beyond the safe handling of one person. Lifting and/or movement should be either undertaken by Mechanical Handling Equipment (MHE) or by sufficient numbers of personnel correctly located around the heater so as to avoid injury or strain. When lifting the handles or handrails, are to be used.

Mechanical lifting

Before lifting the unit the two detachable wheels have to be removed and the front stabilizer fixed in a horizontal position. The wheels then can be stored in the storage department or at the top of the unit. The unit can then be lifted by a truck by using the slots in the skids at the bottom of the unit or lifted by crane with the help of the lifting point, which is welded in the flue outlet of the unit.

Long term storage

If the heater is to be in storage for more than 12 months a preventive maintenance should be performed, see section “12 months maintenance - or 600 hours of operation", page 38. After that the system should be run with fresh and clean fuel to check the performance of the unit. After testing the VAM leave the fuel in the oil system of the unit as it prevents condensation inside the system and keeps all rubber parts lubricated. The long-term storage conditions should be between 0 °C and 30 °C with a humidity no

971145 • Version 2.1 • 22.10.2012

greater than 60 % relative humidity.

33

Service guide Overview Introduction

This section gives the necessary information to help the responsible maintenance personnel at servicing and repairing the heater.

Contents

This section covers the following topics: Topic

34

See page

Preventive maintenance

35

Corrective maintenance

39

Spare parts

58

Hotline

80

Service agreement

81

Preventive maintenance Regularly mainte-

Maintenance has to be performed regularly, as preventive maintenance in three different

nance

steps. This maintenance should only be performed by responsible maintenance personnel.

Warning

Never work on the heater with the power supply cable connected to the power supply!

Warning

Never disconnect the power supply cable from the power source, before the heater has cooled down completely! This can damage the combustion chamber or heat exchanger! For shut down see section “Shutdown of the heater”, page 32.

Tools

For service and maintenance no special tools are required.

Contents

This section contains the following topics: Topic

See page 36

6 months maintenance - or 300 hours of operation

37

12 months maintenance - or 600 hours of operation

38

971145 • Version 2.1 • 22.10.2012

Daily maintenance

35

Daily maintenance Warning

Never work on the heater with the power supply cable connected to the power supply!

Warning

Never disconnected the power supply cable from the power source, before the heater has cold down completely! This can damage the combustion chamber or heat exchanger!

Daily maintenance

At the end of each day, or after eight hours of operation:  Shut the heater down by turning the function switch to 0 (OFF) The burner (if running) will cut off, but the fan will continue running for one to two minutes until the internal heater temperature has dropped below 30 °C. Then the fan will stop.  Disconnected the power connector plug at the power source and perform the following inspection: Step 1

Action Check if there is still enough fuel left in the drum or jerry can for the next period of operation

2

Open the burner compartment cover

3

Drain any accumulated water from the separator by turning the knurled drain cock  on the bottom of the separator counterclockwise. Place an absorbent cloth or paper towel under the drain cock to prevent fuel/water mixture from spilling. Continue draining the water until no longer visible in the bowl

 4

Inspect all fuel hoses and fuel fittings for leaks, breaks or other damage

5

Inspect electrical cables and connectors for loose connections or damaged cables. Check for scraped insulation or exposed wires. Inspect the power cable for breaks, stripped insulation and other damage. Check that the wires are not exposed at the fittings on each end due to bending or pulling on the cable when the fittings are connected to the power source or heater

6

Refer any damage or irregularities to the responsible maintenance personnel

7

Remove debris that may have collected in the inlet grille

8

Restart the heater and check the color of the flue gases leaving the flue stack after a stabilizing time of about 5 minutes from start up. Normally the flue gas will be hardly visible but on cold winter days it can have a white, milky color. If this is the case, the burning process is ok. If dark grey in colour; Stop the heater and the responsible maintenance personnel has to be contacted. See also section “Corrective maintenance”, page 39

36

6 months maintenance - or 300 hours of operation Introduction

Preventive maintenance is to be performed every 6 months or every 300 hours of operation, whatever comes first. The burner operation hours are indicated on the hour meter:

Procedure

Follow this procedure to perform the 6 months (300 hours) preventive maintenance: Step

Action

1

Carry out the procedure for daily maintenance (see page 36)

2

Drain the fuel filter/water sepa-

 

rator and if the filter element is dirty and disassemble the bottom section by unscrewing the assembly screw . Upon reas-

Assembly

screw 

 





sembly ensure the filter element



“Position” “Position” O-ring

is in position towards  and . Also check that the O-ring  is intact and correctly positioned 3

Fig. 17

Remove the complete nozzle holder assembly through the front of the burner "Burner components”, page 47, and clean all dirty parts

4

Unscrew the nozzle and clean the filter. If it is dirty replace the nozzle (0.85/60°) with a new nozzle

5

Check electrode distance and position. If there are cracks in the white porcelain the electrodes have to be changed

6

Clean the burner’s photo cell

7

Clean the burner’s fuel pump filter. If it cannot been cleaned properly a new filter with o-ring has to be mounted

8

Check flow control for impurities. The flow control cannot be disassembled. This means, if it is too dirty it has to be replaced with a new one

9

Check the fuel lance non-return valve for debris, damage and proper closing. Check the quick coupling for tightness, that no false air can enter the fuel line

10

Remove the plate over the fan in the storage compartment and clean the fan wheel

11

Remove the flue pipe and inspect internally for soot deposits. Also check the flue pipe flange to the heat exchanger. Small amounts of soot deposits can be removed with a stiff brush and vacuumed out

12

Remove the burner from the compartment and inspect the combustion chamber through the burner flange hole with a light source. Soot will need to be

971145 • Version 2.1 • 22.10.2012

vacuumed out and any possible products of combustion at the base be cleaned out as well 13

Operate the heater and check all adjustment set points see "Corrective maintenance", page 39

37

12 months maintenance - or 600 hours of operation Introduction

Preventive maintenance is to be performed every 12 months or every 600 hours of operation, whatever comes first. The burner operation hours are indicated on the hour meter:

Procedure

Follow this procedure to perform the 12 months (600 hours) preventive maintenance: Step 1

Action Carry out the procedure for daily and 6-month preventive maintenance, see page 36 and page 37

2

Replace the oil nozzle

3

Dismount the combustion chamber/heat exchanger from the cabinet. Refer to “Disassembly of main parts”, page 55 for detailed instructions on these procedures

4

Turn the Heat Exchanger on its side. Locate the circular cover Cleaning Door on the bottom outside of the Heat Exchanger. Remove all six brass nuts and washers. Remove the circular cover. Carefully remove gasket. Inspect gasket for breaks in its seal. If breaks are found replace gasket

5

Flush through this opening and the flue discharge with high-pressure water cleaner and drain out all dirt and water. This procedure should take place at the unit motor pool or wash rack equipped with an oil/water separator

6

Reassemble the unit and ensure there are no leaks. Use a star pattern for tightening nuts

7

Before mounting the burner check that the burner is assembled and adjusted correct. Refer to “Corrective maintenance”, page 39 for further information

8

Important: Do a test run with the unit after reassembling. Check that there is no visible smoke coming out of the chimney. If this is the case, readjust the burner

Warning

Leaks in the combustion chamber/heat exchanger may result in infiltration of dangerous combustion gases to the heated airflow.

Note

38

White smoke is often present at colder air temperatures. This is a normal condition.

Corrective maintenance Overview Introduction

Corrective maintenance procedures are recommended actions to restore the heater to normal operating conditions for preventive maintenance or to correct operating problems. On completion of each corrective procedure, operate the heater to be sure it has been restored to normal functions. This corrective maintenance should only be performed by responsible maintenance personnel.

Warning

Never work on the heater with the power supply cable connected to the power supply!

Warning

Never disconnect the power supply cable from the power source, before the heater has cooled down completely! This can damage the combustion chamber or heat exchanger! For shut down see section “Shutdown of the heater”, page 32.

Tools

A Bacharach test unit is required to test flue gases. No other test equipment or special tools are required. Standard tools are adequate for corrective maintenance of the heater.

Contents

This sections contains the following topics: Topic

See page 40

Electric components

43

Fuel delivery system components

44

Burner components

47

Burner adjustment

53

Disassembly of main parts

55

971145 • Version 2.1 • 22.10.2012

Fault finding guide

39

Fault finding guide Fault finding

Malfunctions that might occur with operation of the heater are listed below. Reference to actions required to restore heater to normal operating condition are also indicated. If the heater 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 exists and what actions are needed to correct the problem. Problem

Cause

Action

Heater does not operate

No voltage at heater

Check that power cable is cor-

or stops operating. Green

power input

rectly connected to power

indicator lamp on control

source.

panel is not ON. Check power source is turned on providing 1 × 230 V AC; 50 Hz Heater does not operate

No stable voltage

Verify that steady power 1 ×

or stops operating. Green

230 V AC; 50 Hz is being sup-

indicator lamp on control

plied. Reset breaker button by

panel is ON. Red indicator

pressing it in until it locks in

lamps are not ON.

the set position

Circuit breaker button on

Short circuit or high cur- Check electric circuits to fan,

control panel is extended

rent due to component

preheater and oil burner. Reset

fault

breaker button by pressing it in until it locks in the set position

Heater does not operate

Over temperature (OT)

or stops. Green indicator

condition

Set function switch to 0 (OFF)

lamp ON. Red (OT) indica-

Check for blockage in supply

tor lamp ON

or return air ducts, or collapsed duct. Clear out debris or blockage. Correct duct condition. Reset OT thermostat button. Restart heater

Heater does not operate

CO contents too high in

Leave the tent at once after

or stops. Green indicator

the tent

opening the doors and win-

lamp is ON. Red indicator lamp on CO monitor ON.

dows. Check if any running veDANGER!!

Acoustical signal

hicles are standing nearby the heater. Reset the CO monitor and start the unit

Heater does not operate

Out of fuel

Set function switch to 0 (OFF).

or stops. Green indicator lamp ON. Red indicator

Replenish fuel, reset primary

lamp is not ON. Red light

control by pressing the red re-

in burner primary reset

set button and then restart

button ON indicating

heater

Flame Fault Continued overleaf 40

Fault finding guide, continued , continued

Problem

Cause

Action

Heater does not operate

Fuel delivery pressure low Check for low fuel supply. Re-

or stops. Green indicator

or unstable

plenish fuel and restart heater.

lamp ON. Red indicator lamp is not ON. Red light

Check fuel pressure at fuel

in burner primary reset

pump on oil burner

button ON indicating

Air pockets in fuel supply Visibly check for foam in flow

Flame Fault

system

control unit. Listen for hissing sound of air at duct connections and pre-heater casting. Tighten fittings. Replace leaking duct, fittings or casting

Dirt in fuel system

Replace filter - remove dirt from fuel components

Ice or paraffin in fuel sys- Warm up to melt ice and tem

change to correct fuel type according to temperature

Obstructed fuel line

Check for damaged or kinked fuel line

Flame photo cell inopera- Replace photo cell tive Oil burner malfunction

Remove oil burner. Service burner ignition, fuel nozzle and swirler plate

Oil burner primary con-

Remove and repair or replace

trol malfunction

primary oil burner control

Pump drive failure. Burner Disassemble oil burner and refan wheel is jammed.

pair or replace fan wheel

Burner motor operates but no fuel pressure Pump drive-coupling fail- Replace pump drive coupling. ure. Burner motor runs

Replace pump

but no fuel pressure Fuel preheater is not

Change the safety fuse in the

working. Safety fuse in

preheater

the pre heater system has 971145 • Version 2.1 • 22.10.2012

cut off Remote thermostat calls

Internal LIMIT thermostat

Reduce air duct resistance and

for heat but heater cycles

control overrides

use ambient air instead of re-

frequently

circulation Continued overleaf

41

Fault finding guide, continued Fault finding, continued

Problem Black or dark grey

Cause Fuel/air mixture too rich

smoke exhaust from

Check burner flame Air bleed valve sticking open

the burner compartment.

Adjust mixture screw until smoke is white or light grey.

flue stack Fuel spraying inside

Action

Repair or replace fuel flow control

Leaking fuel lines or fittings

Check fuel lines for loose connections or damage. Tighten

DANGER

loose fittings. Replace fuel line

May cause fire. Shut

and fittings if defective

off power to heater. Function switch at 0. OFF. Stand by with fire extinguisher In cold weather op-

Check for ice in fuel fil-

If ice exists, remove filter can-

eration, burner starts ter/water separator lower

ister and bowl. Warm up to

to run, then stops

melt ice and drain water. Reas-

plastic bowl

semble filter/separator unit

42

Electric components Defective electric

If a short exists in the electrical circuit because of a defective fan motor, burner motor

components

or preheater, these components can be isolated to check each one individually. The procedure for checking each of the components is the same. Test each component separately by disconnecting it and checking there is no longer an electrical short.

Warning

Do not disconnect or reconnect electric cables when the heater is operating. Ensure that the heater is shut down and the function switch is set at 0 (OFF) and the power cable disconnected.

Illustration

This drawing illustrates the electric system: No. 

Burner



Pre-heater



Part



Fig. 18

Procedure

Follow this procedure to check which component is faulty: Step 1

Action Disconnect the burner  and pre-heater  plug from the internal electric panel. Push in the circuit breaker button

2

Set the function switch at VENT position and start up the heater.  If the circuit breaker pops, the short cut must be in the fan or the safety thermostats. Shut down the heater and check these components  If the circuit breaker does not pop out, the short cut must be in the burner or pre-heater. Shut down the heater and connect the pre-heater Set the function switch at MAN position and start up the heater:

971145 • Version 2.1 • 22.10.2012

 If the circuit breaker button pops, the pre heater is defective. Shut down the heater and change the pre-heater.  If the circuit breaker does not pop out, the short cut must be in the burner. Shut down the heater and check the burner

43

Fuel delivery system components Introduction

The fuel delivery system maintenance consists of inspecting or replacing the preheater, flow control and filter assembly.

Inspection

To inspect or replace the preheater, flow control or filter, remove the burner from the oil burner compartment.

Illustration, fuel

This illustrates the fuel delivery system:

delivery system



 

No.



Part



Flow control



Hose into flow control from fuel pump



Hose into flow control from filter



Hose out of flow control into preheater









Electrical connection, preheater



Preheater



Oil filter/water separator

Fig. 19 Procedure, filter/-

Follow this procedure to remove the filter/water separator:

water separator Step

Action

1

Lift up the complete assembly from the wall bracket

2

Remove the nut on top of the water separator/fuel filter assembly

3

Remove the two hoses. Hose facing bulkhead of burner compartment (left) goes to the flow control. Hose facing oil burner compartment door (right) comes in from the fuel source

4

Install replacement filter assembly. Connect hose going to the flow control to the left side of the filter head. Connect hose coming in from external hose connection to the right side of the filter head

NB

5

Replace the holder arm on the top and tighten the nut

6

Press down the filter assembly holder arm on the wall bracket

Normally only the filter element has to be changed or cleaned. See section “Preventive maintenance”, page 35. Continued overleaf

44

Fuel delivery system components, continued Illustration, oil

This illustrates the oil preheater:

preheater

  



No. 

Part To fuel pump



From flow control



Plug for cleaning



Operating thermostat (50 °C)



Fuse

 Fig. 20 Procedure, oil pre-

Follow this procedure to remove the oil preheater:

heater Step

Action

1

Remove oil filter/water separator as described above

2

Remove the two screws under the oil preheater which attaches the oil preheater bracket to the bulkhead inside the burner compartment and take the unit out of the burner compartment

3

Disconnect electric cable with plug from the electric panel

4

Remove the hoses

5

Remove the two small screws on the side of the black plastic cover and lift the cover from the preheater

6

Disconnect electric cable from the terminals below the top

7

Install replacement preheater in reverse order. Connect electric cable and install hoses correctly

8

Connect the plug to the control panel and mount the preheater again inside the burner compartment

NB

The cause for replacement is normally a defective heating element, but it can also be failure of the safety thermostat  or the fuse  under the top cover. If a lot of dirt has collected in the canister, this can be emptied out through the opening . Do not forget to fill up with new diesel oil.

971145 • Version 2.1 • 22.10.2012

Continued overleaf

45

Fuel delivery system components, continued Procedure, flow

Follow this procedure to remove the flow control:

control Step

Action

1

Remove oil filter/water separator and preheater as described above

2

Slide the flow control out of its holder

3

Remove flow control and take it out of the burner compartment

4

Remove the three hoses. The hoses are (from left-to-right):  into flow control from fuel pump  into flow control from filter and  out to preheater from flow control

5

Install replacement flow control. Install hoses (from left-to-right); into flow control from fuel pump, into flow control from filter and out to preheater from flow control

6 NB

Slide the flow control into its holder again

The flow control cannot be repaired, but impurities can block the function. If this is the case, try to flush it out with clean fuel.

46

Burner components Illustration

This illustrates the combustion system:  

No. 

Burner plug



Nozzle holder assembly



Primary control



Oil pump



Part

 Fig. 21 Oil burner service

Oil burner servicing consists of cleaning, checking and if needed replacing the following components:  Nozzle holder assembly with nozzle, electrode unit and swirler plate   Primary control with ignition transformer   Oil pump with filter and magnetic valve   Other parts

Procedure

Follow this procedure to extract the burner from the heater: Step

Action

1

Open to the burner compartment

2

Release the locking bar on the left hand side of the burner

3

Slide the burner assembly, with hoses and cables attached, out of the compartment

4

Disconnect the burner plug  from the internal electrical panel and fuel hoses from the oil pump

971145 • Version 2.1 • 22.10.2012

Continued overleaf

47

Burner components, continued Illustration, nozzle

This illustrates the nuzzle holder assembly:

holder assembly





No. 

Part Screw



Oil pipe fitting



Photo cell



 4-5 mm ± 0.5 mm

Fig. 22 2 mm-2.5 mm

 



 Fig. 23 Procedure



No. 

Part Electrode assembly



Fixing screw



Nozzle



Base of nozzle mount



Screw



Swirler plate



Follow this procedure to replace the nozzle: Step

Action

1

Disconnect the oil pipe fitting  from the pump

2

Take out the photo cell  and loosen the screws 

3

Remove the nozzle holder assembly; turn and slide carefully to the left

4

Loosen the screw  and remove the swirler plate  with slide arm out from the holder

5

Remove the fixing screw  and the electrode assembly 

6

Use an adjustable or open-ended wrench to hold the base of the nozzle mount . Use a 16 mm socket wrench to unscrew and remove the nozzle 

7

Inspect the nozzle assembly. Replace nozzle if it is worn or damaged, and the filter if it is too dirty

8

Clean soot from the swirler plate with a brush and inspect for damage or distortion

9

Clean and inspect electrodes. The points should be sharp. Adjust the gap, if necessary, to 4-5 mm ± 0.5 mm. Replace worn or distorted electrodes Continued overleaf

48

Burner components, continued , continued

Step 10

Action Screw the nozzle onto the mount and tighten with an adjustable and a socket wrench

11

Replace the swirler plate assembly with slide arm into the bottom of the holder. Lock with the screw 

12

Replace the electrode assembly and lock with the screw  after correct positioning of the electrodes tips 2 mm - 2.5 mm in front of the nozzle

13

Replace the nozzle holder assembly by carefully sliding in and turning into position

14

Lock the end plate of the assembly with the two screws and replace the photo cell after checking that the window glass is clean

15

Connect the coupling of the oil pressure tube to the mating fitting and tighten with adjustable wrench

971145 • Version 2.1 • 22.10.2012

Continued overleaf

49

Burner components, continued Illustration, burner

This illustrates the burner primary control with ignition transformer:

primary control

No. Part  Protection crankcase  Screws 

Main voltage cable



Fig. 24

 

Fig. 25 Procedure

Follow this procedure to remove the burner primary control: Step

Action

1

Follow step 1 - 3 under nozzle holder assembly

2

Remove plastic crankcase  protective cover by removing all 4 Phillip head screws. The cover has a built in slit to enable careful removal past the copper fuel line

3

Disconnect the main voltage cable 

4

Remove screws  and disconnect wires from motor, photo cell and coil Continued overleaf

50

Burner components, continued Illustration, oil

This illustrates the oil pump:

pump

No. Part  Crankcase  Burner shaft









Nut



Magnetic valve



O-ring



Filter



Bolt

 Fig. 26







 Fig. 27 Procedure

Follow this procedure to clean/replace the filter in the oil pump: Step

Action

1

Disconnect the oil pipe fitting from the pump

2

Remove plastic crankcase  protective cover by removing all 4 Phillip head screws. The cover has a built in slit to enable careful removal past the copper fuel line.

3

Loosen the screw at the burner shaft 

4

Remove the nut  holding the magnetic valve  and remove the valve

5

Remove the oil pump

6

Remove the four bolts  from the oil pump hosing and remove the housing

7

Take out the filter  and clean or replace it. Replace the O-ring  with a new one

8

Assemble in reverse order

971145 • Version 2.1 • 22.10.2012

Continued overleaf

51

Burner components, continued Illustration, other

This illustrates other parts that could need replacement. The replacement of these parts

parts

is self explanatory when referring to the below exploded view of the burner:





  Fig. 28

52

No. 

Part Fan wheel



Motor capacitor



Motor



Coupling

Burner adjustment Procedure, com-

Procedure to adjust the combustion head:

bustion head

Turn the setting screw  clockwise or counter clockwise until the set point from the below table 1 is shown on the regulating rod  and in level with the outside of the nozzle holder end plate . 

No. 

Part



Setting screw



Regulating rod





Nozzle holder end plate

Fig. 29 Combustion ad-

To achieve efficient combustion and high performance output, the table settings below

justment

(table 1) should be followed as a guideline for the adjustment of the burner. A finer adjustment can be made in conjunction with a flue gas analysis with smoke and O2 tester, which should be done after 12 months maintenance. The factory-mounted nozzle is a 0.85 GPH but if a smaller or larger one is fitted the settings have to be altered accordingly. Nozzle

Pump pressure

Fuel consump-

Combustion

Air damper ad-

tion

head adjust-

justment

ment [GPH]

Angle

[Bar]

[Kg/h]

Set-point

Set-point

0.75

60 °

11.0

3.1

2.1

5.8

0.85

60 °

11.0

3.6

2.5

6.0

1.00

60 °

11.0

4.2

3.1

10.0

Table 1 Procedure, air

Procedure to adjust the air damper:

damper

Loosen the screw  and move the indicator towards the required set point. Retighten the screw .

971145 • Version 2.1 • 22.10.2012



No. 

Part Screw

Fig. 30 Continued overleaf

53

Burner adjustment, continued Procedure, oil

Procedure to adjust the oil pump:

pump adjustment

The oil pressure can be read on the gauge  mounted on the oil pump, after having opened the gauge valve . The pressure should read 13 bar and, if not, can be adjusted with a screwdriver at the regulator screw  on the pump. If the correct pump pressure cannot be achieved, check the pump filter, nozzle filter and the filter element in the filter/water separator. Close the gauge valve after the adjustment. Close the valve first after the burner has stopped!!





 Fig. 31

54

No. 

Part Fuel pressure gauge



Regulator screw



Gauge valve

Disassembly of main parts Introduction

The following procedures cover the disassembly of the heater down to unit level. These procedures should be followed in the order presented for ease of disassembly. Reassembly after cleaning or service has to be performed in reverse order. This section leads you through the removal of the following:

Warning

 Burner

 Fuel delivery system

 Control panel

 Heat exchanger

Before performing any disassembly, ensure the heater has been shut down and the power cable disconnected to the heater to prevent possible electrical shock to personnel. Do not disconnect electric cables with the heater operating.

Burner removal

Please follow this procedure to remove the burner: Step

Action

1

Remove the inspection cover

2

Release the locking bar on the left of the burner by rotating the locker bar upwards

3

Pull the burner assembly, with hoses and cables attached, out of the compartment

4

Disconnect the hoses; blue for outlet, red for inlet

5

Disconnect electrical cable. (For oil burner assembly service, refer to the oil burner servicing in “Corrective maintenance”, page 39)

Control panel re-

Please follow this procedure to remove the control panel:

moval

Step

Action

1

Disconnect the burner and the preheater plugs on the main control box

2

Remove the four cap screws that hold the control panel cover

3

Remove the heater control panel by removing the four cap screws located at the bottom of the control panel

4

Disconnect the wires on the terminals in the control box for the fan, thermostats and power supply

5 Fuel delivery sys-

Remove the heater panel through the oil burner compartment cover

Please follow this procedure to remove the fuel delivery system:

tem removal

Step 1

Action Slide the oil filter/water separator out of its holder and take out of the burner

971145 • Version 2.1 • 22.10.2012

compartment 2

Remove the two screws under the oil pre heater and take the unit out of the burner compartment

3

Slide the flow control out of its holder and take it out of the burner compartment Continued overleaf

55

Disassembly of main parts, continued Fuel delivery system removal, continued

Step 4

Action Now with all parts of the fuel delivery system removed from the unit, you can disconnect the fuel hoses from each component

5

Disconnect the hoses. Prior to disconnecting the hoses; make sure all mating hoses and parts are properly marked for proper reassembly. (For fuel system servicing, refer to fuel system service in “Corrective maintenance”, page 39)

Illustration, heat

This illustrates the heat exchanger:

exchanger removal







  Fig. 32 No. 

Part Cap screws



Top housing assembly



Cap screws



Inspection glass



Undercarriage holding brackets



Combustion chamber burner



flange

Fig. 33 Procedure

Please follow this procedure to remove the heat exchanger: Step 1

Action Remove the three cap screws  from around the flue flange and the four cap screws  at the sides of the top housing assembly 

2

Remove the top housing assembly

3

Remove the combustion chamber burner flange  from inside the oil burner compartment. Remove the two cap screws, star-washers and square spacers (13 mm wrench)

4

Remove the two thermostats on the oil burner compartment firewall Continued overleaf

56

Disassembly of main parts, continued , continued

Step 5

Action Remove the two cap screws on both sides of the undercarriage holding the brackets  for the heat exchanger at the rear

6

Lift up at the rear end of the heat exchanger and pull out, taking care to avoid fouling on the two front brackets

7

Remove the three cap screws, outer face, gasket and inspection glass , from the front of the heat exchanger unit. Inspect the gasket and glass and replace if damaged. The sight glass can be replaced without removing the heat exchanger unit by taking the top housing assembly off and removing the glass

971145 • Version 2.1 • 22.10.2012

and gasket from the front

57

Spare parts Overview 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.

When ordering

When ordering, kindly inform us about:  Dantherm spare parts number/text  NATO stock number of parts  Dantherm field unit type  Dantherm 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 individually delivery, if it is part of a group naturally forming a whole or part of a purchased, complete component.

Reservations

Dantherm reserve the right to make this assessment. Dantherm reserve 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.

Contents

This section covers the following topics: Topic

58

See page

Chimney

59

Cabinet parts, top

61

Cabinet parts, bottom

63

Cabinet parts, bottom inclusive fan

65

Heat unit

67

Oil system

69

Oil burner

71

Electrical system, assemblies

74

Electrical system

75

Accessories

78

Chimney

971145 • Version 2.1 • 22.10.2012

Illustration

This drawing illustrates available spare parts for the chimney:

Continued overleaf

59

Chimney, continued Spare parts

Spare part list for the chimney: Index No.

60

Part No.

Description

NATO No.

1.0

207760-080

Flue duct complete

4520-22-123-2108

1.1

207760-080

Flue duct

4520-22-123-2108

1.2

540000

Handle, beech

5340-22-611-9858

1.3

078940

Insulation, muffler

5640-22-611-1577

1.4

073630

Insulation, muffler

5640-22-611-1516

1.5

208910-080

Muffler, flue duct

2990-22-125-4722

1.6

563970

Muffler duct, bottom

4520-22-125-4724

1.7

207761-080

Flue ducting securing straps

4520-22-126-7200

Cabinet parts, top Illustration

This drawing illustrates available spare parts for the top cabinet parts:

971145 • Version 2.1 • 22.10.2012

Continued overleaf

61

Cabinet parts, top, continued Spare parts

Spare part list for the top cabinet parts: Item No.

62

Part No.

Description

Nato no.

2.1

208740-080

Cover for heater

5340-22-609-4331

2.2

796067

Packing, flue gas outlet

5330-22-125-7927

2.3

078310-080

Flashing, flue gas outlet

4520-22-126-7329

2.4

209430-080

Cover, flue gas outlet

4520-22-123-2111

2.5

890010

Cover complete exhaust outlet

4520-22-126-7201

2.5.1

427000

Wire

4010-22-611-9837

2.5.2

540590

Alu – clips 3mm.

5340-22-608-1108

2.6

078560-080

Cover, wheel storage open

5340-22-611-1573

2.7

078020-080

Fittings for chimney

4520-22-126-7325

2.8

079100

Insulation for cover, left

5640-22-607-2579

2.9

079110

Insulation for cover, top

5640-22-607-2643

2.10

079040

Insulation for cover, right

5640-22-607-2664

2.11

079230

Screen, air outlet

5340-22-611-1594

2.12

078360

Insulation holder

4520-22-610-1093

2.13

209070

Air deflector in Rack

4520-22-611-1968

2.14

017852-080

Generator housing

-

2.15

540470

Rubber locking, SOUTHCO

5340-01-082-6421

2.16

213070-080

Cover, generator compart

2510-22-123-2109

Cabinet parts, bottom

971145 • Version 2.1 • 22.10.2012

Illustration

This drawing illustrates available spare parts for the bottom cabinet:

Continued overleaf

63

Cabinet parts, bottom, continued Spare parts

Spare part list for the bottom cabinet parts: Item No.

64

Part No.

Description

NATO No.

3.1

017850-080

Cabinet junction

-

3.2

208280-080

Runner complete, left

5340-22-611-1916

3.3

077340-080

Bottom frame for runner

4530-22-611-1541

3.4

208290-080

Runner complete, right

5340-22-611-1917

3.5

208810

Wheel with axle

2530-22-121-1021

3.5.1

540800

Wheel

2530-22-611-5497

3.5.2

565980

Wheel axle

-

3.6

207750

Locking device for axle

5315-22-611-2290

3.8

561204

Tube for fuel supply lance

4710-22-609-6235

3.9

078220-080

Top cover, burner room

4520-22-611-1543

3.10

079090

Insulation, top cover

5640-22-611-1581

3.11

078380

Insulation holder

4520-22-611-1558

3.12

079080

Insulation partition wall

5640-22-607-2576

3.13

078400

Bracket for insulation

5840-22-611-1559

3.14

079050

Insulation cabinet side

5640-22-611-1580

3.15

079070

Insulation, cabinet bottom

5640-22-607-2583

3.16

078340

Air deflector

4520-22-603-1446

3.17

207820-080

Handle, wheel lock

5340-22-610-6081

3.18

209756

Tube incl. cutting ring

4710-22-608-6138

3.19

544179

Collar nipple 68F 10x1/8 RG

4730-22-608-6096

3.20

612930

Snap coupling nipple

4730-22-608-6094

3.21

543900

Tank bung. complete

4930-22-608-6140

3.22

79030

Screw cap for drum, oil lance

5305-22-608-6142

3.23

477120

Fiber gasket Ø 17,3 x 23 x 2 mm

5330-22-124-5076

3.24

527520

Counter nut 3/8" brass

5310-22-608-6146

3.25

209758

Non-return valve w/stop sleeve

4320-22-608-6104

3.26

295261-U

Fuel supply lance for drum

4930-22-608-6135

3.27

017838

Cover for wheel, complete

2530-22-611-9408

3.28

017834-080

Damper for fresh air

-

Cabinet parts, bottom inclusive fan Illustration

This drawing illustrates available spare parts for the bottom inclusive fan:

971145 • Version 2.1 • 22.10.2012

Continued overleaf

65

Cabinet parts, bottom inclusive fan, continued Spare parts

Spare part list for the bottom inclusive fan: Item No.

66

Part No.

Description

NATO No.

4.1

069858-080

Handle, front

4710-22-611-1504

4.2

069857-080

Handle, rear, left

4710-22-611-1502

4.3

069856-080

Handle, rear, right

4710-22-611-1501

4.4

078100-080

Suspension for handle

4520-25-135-4010

4.5

207890-080

Suspension for supporting

5340-22-124-5071

4.6

207880-080

Suspension for supporting

5340-22-124-5070

4.7

069888-080

Supporting leg

4520-25-135-3451

4.8

213060-080

Front door complete

4520-22-611-2054

4.8.1

529600

Mounting/Testing label

9905-22-125-4864

4.9

891115-080

Bracket, jerry can

7240-22-126-7335

4.10

017922

Fan DDM 9/7

-

4.11

079190

Insulation for fan

5340-22-607-2585

4.12

540470

Rubber locking, SOUTHCO

5340-01-082-6421

4.13

017834-080

Damper for fresh air

-

Heat unit Illustration

This drawing illustrates available spare parts for the heat unit:

971145 • Version 2.1 • 22.10.2012

Continued overleaf

67

Heat unit, continued Spare parts

Spare part list for the heat unit:: Item No.

68

Part No.

Description

NATO No.

5.1

209990

Heat exchanger complete

4520-22-121-1841

5.2

796052

Cleaning door

4520-22-125-7754

5.2.1

560200

Gasket, cleaning door

5330-22-125-7753

5.3

078280

Support for boiler

5340-22-607-2641

5.4

796053

Sight glass complete, heat unit

9340-22-126-7202

5.4.1

560251

Glass

9340-22-123-2118

5.4.2

560230

Gasket for glass

5330-22-123-2117

5.5

078410

Bracket for insulation

5670-22-607-2653

5.6

079060

Insulation for cabinet side

5640-22-607-2580

5.7

565490

Handle for heat unit

5340-22-125-7858

5.8

560141

Gasket, burner flange

5330-22-126-7203

5.9

296147

Collar with lever

4520-22-611-9800

5.11

211651

Support for oil burner

-

Oil system

971145 • Version 2.1 • 22.10.2012

Illustration

This drawing illustrates available spare parts for the oil system:

Continued overleaf

69

Oil system, continued Spare parts

Spare part list for the oil system: Item No.

70

Part No.

Description

NATO No.

6.1

078130

Mounting plate

5340-22-611-9832

6.2

502400

Oil preheater Cpl.

4530-22-125-7312

6.3

524511

Cable and plug, preheater

4540-22-127-0099

6.4

540850

Oil filter

4330-22-257-4024

6.4.1

540852

Counter nut

-

6.4.2

540853

Filter cover

-

6.4.3

540855

O-ring, K-OR 5207x262 NBR

5331-22-600-8989

6.4.4

540860

Filter

2910-22-257-4025

6.4.5

540857

End plates, set

-

6.4.6

540854

Filter glass, cpl.

-

6.4.7

540856

Drain plug

-

6.4.8

540858

Bracket for oil filter

-

6.5

296153

Flow-control Tigerloop cpl.

-

6.6

544331

Hose nipple, bend 6x1/4"

4720-22-127-0103

6.7

543670

Hose clamp, 6-16 mm MH 4

4730-22-127-0101

6.8

544100

Hose nipple, 6x1/4"

4730-22-610-9653

6.9

078131

Pipe plug 1/4", galvanized

-

6.10

295261-U

Fuel supply lance for drum

4930-22-608-6135

6.11

612900

Housing for snap coupling

4730-12-342-5668

6.12

078990-08 Bracket for oil filter

5340-22-124-5072

6.13

796059

Fuel supply hose lance/filter

4720-22-600-8927

6.14

796060

Fuel supply hose, filter/flow control

4720-22-600-8928

6.15

796061

Fuel supply hose, flow/preheater

4720-22-600-8932

6.16

796062

Fuel supply hose, preheat./burner

4720-22-600-8936

6.17

796063

Fuel supply hose, burner/flow

4720-22-600-8939

6.18

515980

Fuse, preheater

5920-25-140-4375

6.19

543741

Fuel hose (30 meters)

4720-22-604-6061

6.20

524190

Oil line grommet

5325-14-277-7602

Oil burner

971145 • Version 2.1 • 22.10.2012

Illustration

This drawing illustrates available spare parts for the oil burner:

Continued overleaf

71

Oil burner, continued Spare parts

Spare part list for the oil burner:: Item No.

Part No.

Description

NATO No.

7.0

501720

Oil burner

4530-25-147-3009

7.1

525390

Cable and plug, burner

6150-22-126-0045

7.2

796014

Collar

4520-22-126-7371

7.3

796013

Lever

5340-22-126-7206

7.4

796069

Photo cell

5980-15-149-8767

7.5

796001

Cover

2910-22-126-7527

7.6

796002

Bracket & Screw

5120-22-126-7528

7.7

796003

Cover for fan housing

4140-22-126-7529

7.8

796004

Air shutter

4820-22-126-7530

7.9

796005

Fan wheel

4520-15-163-0570

7.10

796006

Block

4520-15-163-0569

7.11

796008

Swivel plate

4730-15-170-1643

7.12

796009

Conveyor

5340-22-126-7532

7.13

796011

Burner tube

4530-15-170-1644

7.14

796015

Control box 535SE

4530-15-170-1645

7.15

796016

Capacitor DTR 7889

4530-15-150-7426

7.16

796017

Cable with plug DTR 7890

6115-22-126-7534

7.17

796018

Magnetic coil

4810-15-148-7103

7.18

796019

Shield

5340-22-126-7535

7.19

796020

Pump

2910-15-148-7104

7.20

796042

Gasket

5330-22-126-7207

7.21

796043

Manometer block

6685-22-126-7536

7.22

796044

Air bleed screw

5305-22-126-7537

7.23

796037

O-ring

5330-22-126-7538

7.24

796038

Gasket

5330-22-126-7539

7.25

796039

Threaded pin

5305-22-126-7540

7.26

796040

Screw

5305-22-126-7541

7.27

796021

O-ring

5331-22-126-7542

7.28

796022

Manometer, DTR 7896

6685-15-148-7105

7.29

796070

Crank case

4730-22-126-7543

7.30

796024

Coupling

4530-22-125-7615

7.31

796025

Motor

6105-22-126-7208

7.32

796027

Nipple

4730-22-126-7544 Continued overleaf

72

Oil burner, continued Item No.

Part No.

Description

NATO No.

7.33

796028

Gasket

5330-22-126-7545

7.34

796045

O-ring

5331-22-126-7546

7.35

796046

O-ring

5331-22-126-7547

7.36

796029

Solenoid valve

4810-15-148-7106

7.37

796030

Filter

4320-15-168-0568

7.38

796031

O-ring

5331-15-120-5467

7.39

796047

Adjusting device

4820-22-126-7549

7.40

796032

Hose connection, DTR 7889

4730-22-126-7550

7.41

796033

Shaft seal Hose connection, DTR 7889 5330-22-126-7551

7.42

796034

Nozzle holder

4820-22-126-7552

7.43

796035

Pressure tube

4720-22-126-7209

7.44

502130

Electrode assembly, DTR 7571

4520-25-135-3720

7.45

796048

Service kit for oil burner

5330-22-125-1427

7.46

501870

Oil nozzle

4530-22-125-1426

971145 • Version 2.1 • 22.10.2012

, continued

73

Electrical system, assemblies Illustration

This drawing illustrates available spare parts for the assemblies in the electrical system:

Spare parts

Spare part list for the assemblies in the electrical system: Index No.

74

Part No.

Description

NATO No.

8.1

017922

Fan DDM 7/9

-

8.2

207830

Oil supply assembly

2910-22-611-1906

8.3

501720

Oil burner

4530-25-147-3009

8.4

017916

Control panel VA-M 40

-

8.5

031782

Power supply cable with plug

-

8.6

018668

Thermostat w/ bracket, cable and plug -

Electrical system

971145 • Version 2.1 • 22.10.2012

Illustration

This drawing illustrates available spare parts for the electrical system:

Continued overleaf

75

Electrical system, continued List

Spare part list for the electrical system: Index No.

Part No.

Description

NATO No.

9.1

019156

Jacket for control panel

-

9.2

017921

Printed circuit board

-

9.3

018656

Ribbon cable

-

9.4

191368

Wiring diagram VA-M 40 Boost

-

9.5

017844

Cover for control panel

-

9.6

296144

Plug for Carbon Monoxide (CO)

-

9.7

296145

Plug for thermostat

-

9.8

892250

Rotary switch

5930-22-123-2123

9.9

527540

Counter nut PG13,5 perfect

5975-12-167-9735

9.10

511630

ETA relay

5925-12-180-9321

9.11

527033

Cable entry PG13,5 perfect

-

9.12

367191

Terminals (4 poles)

-

9.13

018653

Terminals (8 poles)

-

9.14

018598

Terminals (5 poles)

-

9.15

519300

Hour meter UWZ 48 ED 220-240

6645-22-607-8426

9.16

524280

Cartridge socket

5935-22-611-9841

9.17

524710

Insert socket

5935-22-608-7687

9.18

524260

Insert socket

5935-22-608-7683

9.19

527000

Cable gland PG13,5

5975-22-611-9842

9.20

477150

Fiber packing

5330-22-602-7827

9.21

077590

Mounting plate

5340-22-611-1542

9.22

527540

Counter nut PG13,5 brass

5975-12-167-9735

9.23

527010

Screwed cable connection

5975-22-611-9844

9.24

527560

Counter nut PG16, brass

5975-12-167-8610

9.25

891110

Thermostat, OT + packing

4520-22-126-7211

9.25.1

560450

Gasket, OT thermostat

5330-22-608-9964

9.26

524050

Rubber sleeve 18 x 22 x 27 x 1.5

5325-22-611-4944

9.27

552574

Cable, combi thermostat

6150-22-611-2111

9.28

891100

Thermostat, combi + packing

4520-22-126-7212

9.28.1

560440

Gasket, combi thermostat

5330-22-608-9969

9.29

018655

Circuit board with diodes

-

9.30

031782

Power supply cable with plug

-

Monitor

Continued overleaf

76

Electrical system, continued , continued

Index No.

Part No.

Description Thermostat w/bracket, cable and

NATO No.

9.31

018668

-

9.31.1

513420

Thermostat RT 103

6685-22-609-1770

9.31.2

552569

Cable for thermostat

-

9.31.3

078349-080 Bracket for thermostat RT 103

6685-22-609-1771

9.31.4

524651

Plug for thermostat

-

9.32

540970

Blind fastener RM 10902 PVC

-

9.33

025432

Carbon Monoxide (CO) Monitor

-

971145 • Version 2.1 • 22.10.2012

plug

77

Accessories Illustration

This drawing illustrates available spare parts for accessories:

Continued overleaf

78

Accessories, continued List

Spare part list for accessories: Index No.

Part No.

Description

NATO No.

10.0

295031-080

Air hose, insul. 2 m with spigot

4720-22-611-9589

10.0

295030-080

Air hose, insul. 3 m with spigot

4720-22-125-7612

10.1

428230

Insulated hose, Ø225 3 m

4720-01-272-5744

10.1

428231

Insulated hose, Ø225 2 m

4720-22-611-9838

10.2

543620

Clip for hose, Easyclip

4730-22-121-1783

10.3

295090-080

Hose socket, male RAL6014

4520-25-135-4014

10.4

295150-080

Spigot for coupling RAL 6014

4730-22-121-2628

10.5

018668

Thermostat w/ bracket, cable and

-

10.6

295060

Dry powder extinguisher

4210-25-132-7526

10.7

209759-U

Oil lance for jerry-can

4930-22-608-6093

10.8

540200

Jerry can 20 l

7240-22-124-4444

10.9

295330

Air distributing hose, complete

4720-22-123-2734

plug

without wire 10.9

295331-080

Air distribution hose, complete with 4720-22-126-0495 wire

295015-080

Y-distribution complete

4730-22-121-9844

10.11

428436

Storage bag

4720-99-402-0137

10.12

971145

Service manual

-

10.13

025432

Carbon Monoxide (CO) Monitor

-

971145 • Version 2.1 • 22.10.2012

10.10

79

Hotline Introduction

The After Sales Support Department of Dantherm is ready to help you in case of a problem.

Information

Please help yourself and us by having the following information prepared before making the call: Your name Company name

Country

Phone number

Email

Type (unit)

Serial No. (unit)

Site/location (unit)

Description of the

Here you can write down a description of the problem:

problem

Contact

Contact Dantherm, ask for the service department and help will be provided as soon as possible:

80

Phone:

+45 96 14 37 00

Fax:

+45 96 14 38 00

Email:

[email protected]

Service agreement Introduction

The unit includes mechanical parts such as fans, dampers, compressors etc. 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. Dantherm offers to do this maintenance as well as corrective and emergency repair on the units so that they at all times will operate according to factory standards.

Preventative

A preventative maintenance visit is a planned visit on a site. The visit could include the

maintenance visit

following:  An initial computer test, simulating various temperatures  Cleaning of the unit  Visual inspection of the unit – checking for leakages, corrosion etc.  A final computer test of the unit  Completion of a inspection report Some of the activities above are not relevant for your product. The visit can also include other activities, for example battery checks.

Corrective and

In case of malfunctions of the product Dantherm offers to do corrective as well as

emergency repair

emergency repair on the climate units. Agreements will be made with the customer on response time and price.

Setup

Dantherm 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 – and the overall responsibility for the agreement will be Dantherm’s.

Further infor-

For further information about a service agreement in your country or region, please

mation

contact: Henrik Hersted After Sales Support Manager Dantherm Phone: +45 9614 4767 Mobile: +45 2399 4066

971145 • Version 2.1 • 22.10.2012

[email protected]

81

Technical information Overview Introduction

This section gives all important technical data for the heater and a complete wiring diagram for the responsible maintenance personnel.

Contents

This section covers the following topics: Topic

82

See page

Technical data

83

Wiring diagram

84

Technical data Data

Data and dimensions on the cabinet are shown in the following table: Specification

Value

Nominal heat, input

40 kW

Nominal heat, output

38 kW

Fuel consumption, max.

3.4 l/h

Air flow @ 150 Pa/0 Pa

1,445 m³/h/2,125 m³/h

Voltage, frequency

1 × 230 V AC; 50 Hz

Max. running current

8,2 A

Max. power consumption

1000 W

Weight

129 kg

Dimensions (L × W × H)

1400 × 700 × 795/890 mm

Duct connections (Ø)

225 mm

Operating range

- 40 °C to + 30 °C

Storage temperature

0 °C – 30 °C

Storage humidity, max.

60 % RH

Approved fuels

F34 (AVTUR (FSII)) or JP-8 or JET A-1 (b), F35 (AVTUR) or JET A-1, F44 (AVCAT) or JP5 or TURBO 5,

971145 • Version 2.1 • 22.10.2012

F54 (Dieso), & F58 (KeroB)

83

Wiring diagram Diagram, part 1

This is the wiring diagram part 1 for the heater:

Continued overleaf

84

Wiring diagram, continued

971145 • Version 2.1 • 22.10.2012

Diagram, part 2

This is the wiring diagram part 2 for the heater:

Continued overleaf

85

Wiring diagram, continued Legend

This legend refers to the wiring diagrams on the previous pages: Ref.

Description

Ref.

Description

B1

OT thermostat

R2

Heating element oil pre heater

B2

Fan thermostat

S2

Function switch

B3

Limit thermostat

Y4

Magnetic valve burner

B4

CO monitor

X1

Terminal strip printed circuit board

C1

Capacitor burner motor

X1.1-2

Connection plug oil burner

F1

Thermo fuse control current

X2

Terminal strip printed circuit board

LD

Photo cell burner

X2.1-2

Connection plug oil pre heater

M1

Burner motor

X3

Terminal strip printed circuit board

M2

Fan motor

X3.1-2

Connection plug room thermostat

P1

Hour meter burner

X4

Terminal strip printed circuit board

RT

86

Room thermostat

X4.1-2

Connection plug CO monitor

971145 • Version 2.1 • 22.10.2012

Index accessories ................................................................. 19

fresh air openings ................................................. 11; 12

air circulation system ............................................ 13; 14

fuel........................................................................ 15; 83

air distribution duct .............................................. 19; 24

fuel consumption ........................................................ 83

air inlet ....................................................................... 14

fuel delivery system ............................................... 44; 55

air recirculation ........................................................... 22

fuel handling ............................................................... 30

approved fuels ............................................................ 83

fuel hose connection ................................................... 21

AUTO .......................................................................... 27

fuel pre-heater ............................................................ 15

burner ....................................................... 37; 39; 43; 47

fuel pump.................................................................... 13

burner flameout protection ......................................... 17

fuel starvation symptoms ............................................ 30

burner plug ................................................................. 47

fuel system .................................................................. 15

burner primary control ................................................ 50

function switch ...................................................... 16; 27

burner removal ........................................................... 55

gauge .................................................................... 15; 54

burner shaft ................................................................ 51

gauge valve ................................................................. 54

cabinet ........................................................................ 11

general information ....................................................... 7

CO failure.................................................................... 18

handle ......................................................................... 23

CO override ................................................................. 17

heat exchanger............................................................ 13

combustion ........................................................... 13; 47

heat exchanger removal .............................................. 56

combustion adjustment............................................... 53

hinged door................................................................. 11

combustion head ........................................................ 53

hotline ......................................................................... 80

combustion system ............................................... 13; 47

hour-meter ........................................................... 16; 18

connector for CO monitoring ...................................... 16

inlet openings ............................................................. 11

connector for remote thermostat ................................ 16

inspection glass..................................................... 13; 56

contact Dantherm Air Handling ................................... 80

insulated air duct................................................... 19; 24

control circuit.............................................................. 18

Introduction .................................................................. 3

control panel ............................................................... 16

knob............................................................................ 25

control panel removal ................................................. 55

led ......................................................................... 16; 17

control system ............................................................ 16

legend ......................................................................... 86

copyright ...................................................................... 7

lifting .................................................................... 11; 33

corrective maintenance ............................................... 39

main voltage cable....................................................... 50

coupling ................................................................ 37; 52

maintenance .................................................... 34; 35; 82

crankcase .................................................................... 51

MAN ............................................................................ 27

daily maintenance ................................................. 29; 36

max. power consumption ............................................ 83

declaration of conformity .............................................. 7

max. running current................................................... 83

defective electric components ..................................... 43

Mechanical Handling Equipment .................................. 33

dimensions ................................................................. 83

mechanical lifting ........................................................ 33

direct driven fan .......................................................... 14

models .......................................................................... 3

disassembly of main parts........................................... 55

motor .......................................................................... 52

dry powder extinguisher ............................................. 19

motor capacitor ........................................................... 51

duct connection ........................................ 12; 14; 22; 83

Motor capacitor ........................................................... 52

duct openings ............................................................. 12

nominal heat input ...................................................... 83

efficiency .................................................................... 22

nominal heat output .................................................... 83

electrical connection, preheater .................................. 44

nozzle ................................................................... 48; 53

electrode assembly ..................................................... 48

nozzle holder assembly ................................... 37; 47; 48

exhaust gas .......................................................... 13; 21

oil burner .................................................................... 13

fan .............................................................................. 52

oil burner service ......................................................... 47

fan wheel .................................................................... 52

oil filter/water separator.............................................. 44

fault finding .......................................................... 39; 40

oil lance................................................................. 10; 15

field applications ......................................................... 10

oil pipe fitting.............................................................. 48

filter ...................................................................... 51; 54

oil pressure ................................................................. 54

filter/water separator ............................................ 15; 54

oil pump.......................................................... 47; 51; 54

flow control........................................................... 15; 44

operating range ........................................................... 83

flue outlet opening ................................................ 11; 12

operation at high altitudes .......................................... 31

flue stack .................................................. 10; 11; 13; 21

operation of the heater ................................................ 27

forklift......................................................................... 11

O-ring ......................................................................... 51

fresh air intake ...................................................... 14; 21

OT failure .................................................................... 17

87

overheat protection ............................................... 17; 29

shutdown of the heater ............................................... 32

oxygen ........................................................................ 31

skids ........................................................................... 11

parking stand ........................................................ 11; 23

sledge runners ............................................................ 11

performance characteristics ........................................ 10

solenoid valve.............................................................. 13

photo cell .................................................. 13; 37; 41; 48

spare parts .................................................................. 58

power.......................................................................... 18

accessories ............................................................. 78

power supply cable ..................................................... 16

cabinet parts, bottom ............................................. 63

preheater .................................................................... 44

cabinet parts, bottom inclusive fan ......................... 65

pre-planning ............................................................... 21

cabinet parts, top ................................................... 61

preventive maintenance ............................ 35; 37; 38; 39

chimney .................................................................. 59

primary control ........................................................... 47

electrical system ..................................................... 75

product description ....................................................... 9

electrical system, assemblies .................................. 74

protection crankcase ................................................... 50

heat unit ................................................................. 67

pump .......................................................................... 15

oil burner................................................................ 71

pump pressure ................................................ 15; 53; 54

oil system ............................................................... 69

recycling ....................................................................... 7

standard configuration ................................................ 10

refuel and restart ........................................................ 30

storage .................................................................. 11; 33

repairing ..................................................................... 34

storage bag ................................................................. 19

replacement of parts ................................................... 10

storage compartment .................................................. 11

reset button ................................................................ 16

storage humidity ......................................................... 83

reset circuit breaker .................................................... 18

storage temperature .................................................... 83

return air duct ............................................................. 22

supply air duct ............................................................ 21

room thermostat ................................................... 17; 22

swirler plate ................................................................ 48

safety and warning instructions..................................... 4

technical data ........................................................ 82; 83

definitions ................................................................ 4

technical information................................................... 82

electrical hazards ..................................................... 5

thermostat ............................................................ 25; 28

handling and use of fuel ........................................... 5

tools ...................................................................... 35; 39

location and exhaust fumes...................................... 6

total shutdown ............................................................ 32

physical handling ..................................................... 6

transport and storage .................................................. 33

safety shutdown .......................................................... 13

user’s guide ................................................................ 20

service access ............................................................. 11

VENT ........................................................................... 27

service agreement ....................................................... 81

voltage ........................................................................ 83

service department...................................................... 80

weight ......................................................................... 83

service guide ............................................................... 34

wheels ......................................................................... 11

set-up............................................................. 10; 21; 23

wiring diagram ...................................................... 82; 84

shutdown .................................................................... 32

88

89

971145 • Version 2.1 • 22.10.2012

90

Contact Dantherm

Dantherm Air Handling A/S

Dantherm Air Handling AS

Dantherm Air Handling AB

Marienlystvej 65

Postboks 4

Virkesgatan 5

7800 Skive

3101 Tønsberg

614 31 Söderköping

Denmark

Norway

Sweden

Besøksadresse: Skallestad, Nøtterøy Phone +45 96 14 37 00

Phone +47 33 35 16 00

Phone +(0) 121 130 40

Fax

Fax

Fax

+45 96 14 38 00

+47 33 38 51 91

+(0) 121 133 70

[email protected]

[email protected]

[email protected]

www.dantherm.com

www.dantherm.no

www.dantherm.se

Dantherm Air Handling (Suzhou) Ltd.

Dantherm Limited

Dantherm Air Handling Inc.

Bldg#9, No.855 Zhu Jiang Rd.,

12 Windmill Business Park

110 Corporate Drive, Suite K

Suzhou New District, Jiangsu

Windmill Road, Clevedon

Spartanburg, SC 29303

215219 Suzhou

North Somerset, BS21 6SR

USA

China

England

Phone +86 512 6667 8500

Phone +44 (0)1275 87 68 51

Phone +1 (864) 595 9800

Fax

Fax

Fax

+86 512 6667 8500

+44 (0)1275 34 30 86

+1 (864) 595 9810

[email protected]

[email protected]

www.dantherm-air-handling.com.cn

www.dantherm.co.uk

www.dantherm.com

971145 • Version 2.1 • 22.10.2012

[email protected]

91

*971145* 971145 Dantherm Air Handling A/S Marienlystvej 65 7800 Skive Denmark www.dantherm.com [email protected] 92