Air Conditioning

DA Betjeningsvejledning DVC-styring Side 3

EN User’s guide for the DVC controller Page 23

DE

FR

AC-M5 W MKII

Service manual

EN

No. 062367 • rev. 1.0 • 15.02.2011

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

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

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Introduction Overview

Introduction This is the service manual for the Dantherm Air Handling A/S AC-M5 W MKII unit. The below table of contents gives an overview of the main sections.

Serial number This manual covers units with serial numbers equal or higher than: XXXXXX1158513

Syntax Please note that this unit comes as standard with a 2 KW heating element installed:

Dantherm number Code*) NATO stock number

322036 AC-M5WE-H020-B-BS381C285 -

*) The code is specified on the data plate, which is placed on the outside of the unit. See the explanation of the syntax code on page 5

Warning It is the responsibility of the operator to read and understand this service manual and other information provided and to use the correct operating procedures. Air conditioners should only be operated by qualified (trained) personnel and the repair of the cooling circuit and electrical system is to be done only by skilled service people. Failure to do so can result in personal injury or equipment damage. Read the entire manual before the initial start-up of the air conditioner. It is important to know the correct operating procedures for the air conditioner and all safety precautions to prevent the possibility of property damage and/or personal injury.

Table of contents This service manual covers the following main topics:

Topic See page

General information 4

Syntax 5

Product description 6

Functional description 15

User’s guide 16

Service guide 25

Technical information 36

4

General information

Introduction This section gives the general information about this service manual and about the unit.

Manual, part number

Part number of this service manual is 062367.

Target group The target groups for this service manual are the: • Users of the unit • Technicians who install and maintain the unit

Copyright Copying of this service manual, or part of it, is forbidden without prior written permission from Dantherm Air Handling A/S.

Reservations Dantherm Air Handling A/S reserves the right to make changes and improvements to the product and the service manual at any time without prior notice or obligation.

EC-Declaration of Conformity

Dantherm Air Handling A/S, Marienlystvej 65, DK-7800 Skive hereby declare that the units mentioned below:

AC-M5 W MKII, product no. 322036: are in conformity with the following directives:

2006/42/EEC Directive on the safety of machines 2006/95/EEC Low Voltage Directive 2004/108/EEC EMC Directive 97/23/EEC The Pressure Equipment Directive 94/62/EEC Packaging Directive

- and are manufactured in conformity with the following harmonized standards: EN 12100 Machine Safety EN 60 335-1 Low Voltage EN 60 335-2-40 Low Voltage DEF-STAN 59-411, part 3 Land Class C Military EMC Standard EN 378 Refrigeration systems

Skive, 16.09.2009

Recycling The unit is designed to last for many years. When the time comes for the unit to be re-cycled, the unit should be recycled according to national rules and procedures to pro-tect the environment.

Quality Manage-ment System

Dantherm Air Handling A/S has implemented a Quality Management System according to EN/ISO9001. The system is supplemented with an Environmental Management Sys-tem according to EN/ISO14001. Both systems are third-part approved and certified, by Bureau Veritas Certification. During 2005 & 2006 the Management Systems are supplemented with business-routines with regards to Safety. These routines fulfil the requirements stated in the in-ternational standard for Safety Management Systems OHSAS18001.

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Syntax

Introduction All products are named according to a syntax giving information about the specific unit configuration.

Example This example is not necessarily related to the specific unit this manual describes:

AC-M5W-H070-B-225-R6014-G3F7-SH-X1

AC Air conditioner VA Heater (diesel)

M Military unit

5 5 kW nominal performance

W Window mount S Split unit

H Electric heat

020 2000 W heat 070 7000 W heat 100 10000 W heat 200 20000 W 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 connection 315 315 mm connection 400 400 mm connection

R6014 Four digit RAL colour code or 33446 FED-STD 595B code

G3F7 Two filters, one G3, one F7

S Compressor softstarter included H HPFI included

X Specifics/custom

6

Product description Overview

Introduction This section will give you a description of the AC-M5 W MKII and its functionality.

Content The section covers the following topics:

Topic See page

General description 7

Description of the cooling system 10

Description of the control board 12

Accessories 14

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General description

Introduction This section gives a description of the unit as a whole. The following sections describe the different parts in detail.

General The AC-M5 W MKII air conditioner is made of high quality materials and the production process is subject to constant quality checking. The instructions in this service manual have been prepared to ensure that, when followed, this air conditioner will provide long and efficient service.

Typical applica-tions

The AC-M5 W MKII is designed to be built into a trap door system, which is mounted in the container. Optionally in welding frame. The AC-M5 W MKII is designed to be compatible with shelters equipped with existing AC-M5 W. All dimensions are translated into the new design. This easily upgrades the container to AC-M5 W MKII. Dantherm air conditioner model AC-M5 W MKII is designed primarily to deliver cooling or heating to containers and other types of temporary shelters. Other typical applications can be:

• Cooling of hot confined areas where personnel are working • Cooling of equipment to prevent damage or malfunction due to overheating • Re-circulating air in closed shelters

Functionality The function of the AC-M5 W MKII is based on a cooling circuit and two powerful fans. The front section (internal) contains the evaporator and the evaporator fan, which draws warm ambient or re-circulated air through the cold evaporator coil and blows out the cooled air through the discharge. The back (external) section of the unit houses the condenser fan and the condenser coil, which returns the heat taken from the indoor air to the surrounding atmosphere.

Lifting system By means of a fork lift the air conditioner is lifted from the outside and in, into the trap door system. Components on the below drawing from left to right:

• Front grill • Welding frame • Trapdoor system • AC-M5 W MKII

Continued overleaf

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General description, continued

Cabinet

Front (evaporator side)

The unit is a strong construction made in 0.9 mm sheet metal plates, which are galvanised and protected against corrosion. Outside finish painting is standard NATO green, RAL6014 with infrared anti-reflecting qualities. The condensate drain is located un-der the unit. It is snapped in place by a snaplock in the long slot at the bottom of the unit. The drain can be pried out using a screwdriver if needed during service or if a hose extension is desired. At the front of the unit there is a re-movable air filter for the re-circulated air intake on the left hand side and a discharge grill for the cooled outlet air at the right hand side. The operation panel for the unit is placed under the discharge grill for the cooled air. The discharge grill can be removed for inspection and service purposes.

Rear (condenser side)

Continued overleaf

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General description, continued

Air flows Only the Air flowing through the evaporator core enters through a standard washable, removable air filter. On the discharge side of the evaporator section there is a discharge grill. This grill is non adjustable as not to compromise the Land Class C Noise level, described in DEF-STAN-59-411. As the AC-M5 W MKII is unavailable with fresh air intake the air being processed in this unit is re-circulated air within the shelter.

Top view

Part Function Part Function

Recirculated air intake Condenser

Discharge of cooled air in container Centrifugal fan

Condenser air intake Axial fan

Condenser air discharge Heater element

Evaporator - -

Heater The heater coils installed are equipped with a reset button for OT (overheating) ther-mostat on top of the unit. For reset of the OT, please see section ”Fault finding guide”, page 33

Built-in thermostat The AC-M5 W MKII has a built-in thermostat which monitors the return air temperature. The temperature is set on the dial on the control board.

10

Description of the cooling system

Description In the front section of the unit the evaporator (cooling coil) is mounted together with an expansion valve and the sight glass. The condenser, the compressor and the rest of the components are housed in the rear section. The cooling circuit is completely sealed and filled with refrigerant (R134a). Description of the cooling process: From the receiver liquid refrigerant will flow under high pressure through the liquid line dryer and the sight glass to the thermostatic expansion valve. Here the refrigerant is led into the evaporator where it evaporates at low pressure and low temperatures. The evaporated refrigerant is drawn back to the hermetic compressor and compressed. From the compressor the refrigerant vapour goes to the condenser, where it is cooled to below dew point and condensed to liquid refrigerant because of the cooling effect from the condenser airflow. Both evaporator and condenser are heat exchangers with copper tubes and coated aluminium fins. By the cooling of the evaporator air stream heat is adapted to the cooling circuit and released in the condenser together with the electric energy consumption of the compressor. At ambient temperatures below 18-20 °C, where cooling is not normally required, the humidity in the airflow will form ice on the evaporator. This will generate a Low pressure (LP) condition. The compressor will stop until the ice has melted. At high ambient tem-peratures (above 60 °C) the cooling of the condenser airflow will be too low, and the high pressure results in cut out of the HP pressure switch.

Illustration This illustrates the cooling system and internal compo-nents of the AC-M5 W MKII:

Continued overleaf

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Description of the cooling system, continued

Parts and their function

This table gives an overview and short description of each part shown in the previous illus-tration:

Part Function

Evaporator Absorbs heat from the shelter by cooling down the circulated air

Condenser Emits the heat generated in the tent/room to the outside air

Centrifugal fan For internal air flow

Axial fan For external air flow

Compressor Circulates the fluid in the cooling system

Expansion valve Supplies the correct quantity of coolant into the evaporator

Sight glass Enables a visual check of the coolant

Control panel Control panel with function switch and indicator lamp(s)

Schematic view This schematic drawing illustrates the different parts of the cooling circuit:

Fig. 1

Part Function Part Function

Compressor Expansion valve

Condenser Evaporator

Receiver HP pressure switch

Liquid line drier Schrader valve

Sight glass Heating element

10

12

Description of the control board

Introduction This section gives a detailed description of the control board. A description of how to start up, for example, is found in section “User’s guide”, from page 16. The control panel on the front side contains all the controls required for normal opera-tion.

Illustration This illustrates the control board of the AC-M5 W MKII:

Part/function This table gives an overview of each part of the control panel:

Part Function

Function switch

The function switch selects the operating mode. For a detailed description of the modes please see section “Functional description”, page 15

Evaporator fan speed switch

Switch for high or low evaporator fan speed:

Speed Description

low/I Normally used if the noise level should be low and the maximum cooling/heating capacity is not required

high/II Normally used if a maximum cooling/heating ca-pacity is required

Continued overleaf

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Description of the control board, continued

Part/function, con-tinued

Part Function

Indicator lamps

On the operator panel there are 4 control lamps, indicating the following from left to right:

Symbol Color Description

- IR connection to serial port. For Dan-therm service technician only

Green Cooling circuit is operating to lower tem-perature. Normal operation is green

Yellow The unit is operated inefficiently. This will self reset in time

Cooling

Red The compressor current draw is outside specified window. (indicating a faulty compressor)

This will reset when functions switch is briefly switched to off position

Power

Green Always green, provided there is 230 V AC connected to the unit.

Note: Also green when the functions switch is in Off position Must be completely off when servicing unit/changing filter

Green Indicating the heater coil is working to raise temperature

Heating Red The heater coil current draw is outside specified window. (indicating an open circuit like OT fault)

This will reset when functions switch is briefly switched to off position, and/or the OT reset button is depressed.

OT fail: Overheat thermostat failure. See also section “Fault finding guide”, page 33

Green whenever one or both fans are running

Fan op-eration

Red One or both fans have a defect chasing the current draw out of specified window

Temperature dial for room temperature

Power cable

14

Accessories

Introduction Further information about each separate accessory is available upon request to Dantherm Air Handling A/S.

List Below you will find a complete list with drawings, description and article numbers of available accessories:

Accessory Illustration Description Article No./NSN No.

Trap door system

Trap door system 322037/-

Frame

Frame for welding into corrugated container

019502/-

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Functional description

Function switch The function switch allows the user to switch between different modes. The modes are described below.

Operation modes This gives a description of each selectable mode:

Mode Description

Ventilation operation

The evaporator fan will operate according to the speed selected on the evaporator fan speed switch

O (OFF)

All functions will immediately stop and only the illuminated green lamp will indicate that the power is still on.

Warning: The evaporator fan will run according to speed selector, even with the mode selector in “0” OFF position, if temperature inside the AC-M5 W MKII cabinet exceeds 50 °C. This will automatically shut down when temperature inside the AC-M5 W MKII cabinet drops below 35 °C

AUTO

The controller will operate to achieve the selected temperature set on the temperature dial. The controller decides whether to activate cooling or heating, in order to maintain desired temperature.

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User’s guide Overview

Introduction This section describes how to utilise the different functions.

Compressor pro-tection

The compressor unit is protected from start up overheating. This is done by in-troducing a 30 sec start up delay on compressor start up on every cooling cycle start. Rapid adjustments of temperature dial will prevent the compressor from starting.DO NOT cycle the temperature dial as this will cause the cooling to NEVER come on.

Contents This section contains the following topics:

Topic See page

Make the AC-M5 W MKII ready for use 17

ACU removal 21

Starting up and shutting down the air conditioner 22

Transport and lifting of the unit 24

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Make the AC-M5 W MKII ready for use

Tools List of tools required: • 5 mm Allen key • TX 15 screwdriver • 10 mm spanner or socket wrench

Trap door system Read this recommendation before installing the trap door:

Step Action

1 With an angle grinder, remove rust and oxide scales from the contact sur-face of the welding frame. Important: Keep grinding until the surface is blank.

2 Degrease and clean the contact surface. Use alcohol or the like.

3 Cover the contact surface with a layer of zinc or a similar anodic solution. Important: Follow the guidelines on how to use the solution (in regard to dry-ing).

4 When the corrosion protection is ready, mount the trap door in the welding frame.

5 Make sure all bolts are surely tightened.

6 When mounted, carefully seal the opening between the welding frame and the trap door to prevent moist from penetrating.

Follow these steps to install the unit in the door trap system:

Step Action

1 Remove the door from the trap door system by removing the two Allen screws that hold the door

Continued overleaf

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Make the AC-M5 W MKII ready for use, continued

Trap door system, continued

Follow these steps to install the unit in the door trap system

Step Action

2 Loosen the 21 screws that hold the front grill. Dismount the front grill and the filter

3 Lift the unit to the location of the trapdoor by means of a forklift

4 Push the ACU gently into the trapdoor. Care should be taken to ensure that the power cable is not snagged when the ACU is pushed inwards

5 Align the two M8 holes roughly with the big Ø25 mm holes in each horn when pushing in the ACU

Continued overleaf

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Make the AC-M5 W MKII ready for use, continued

Trap door system, continued

Step Action

6 Screw in loosely the two 8 mm finger screws dangling in wires on each horn. This is to secure the ACU while re-mounting the front grill. It is also the way to secure the ACU during filter change/cleaning

Care should be taken to avoid damage to your fingers when performing this task

7 Remount the filter, the front grill and the 17 screws.

Do not remove the two M8 finger screws just yet

8 Mount the 2 draw out roller mechanisms (delivered sepa-rately in a small bag) as shown in the pictures in step 5 and 6

Continued overleaf

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Make the AC-M5 W MKII ready for use, continued

Trap door system, continued

Step Action

9 Next mount the buffer consoles. One for each side

10 Connect power

11 Re-mount the door of the trap door system and shut it securely using the snap locks from the outside of the shelter

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ACU removal

Procedure Follow this procedure to remove the ACU:

Step Action

1 Switch off the ACU and remove the power cable from the shelter connection

2 Ensure ACU is in the filter change/service position, with the securing knobs loosely fitted in the large holes in the horns

3 Unscrew the 19 torx 15 screws and detach the front grill of the unit

4 Remove the filter and the exhaust/discharge grill

Do not harm the EMC seal in the front grill

5 Stowed away the power cable inside the ACU for convenience

6 Remove the flap from the door trap system by removing the two Allen screws that hold the door

7 Unscrew the securing knobs.

Push the ACU by hand onto the forks of a forklift, placed on the outside of the shelter.

Be careful not to harm the power supply cable. Alternatively the power cable can be coiled and placed inside the cabinet in these steps.

Do not harm the EMC seal on the trapdoor

8 Strap the ACU securely to the forks while descending to the ground. Do not forget the power cable as this is the only cable connected to the ACU at this point

9 Remount the front grill and discharge grill to the ACU by the 19 torx 15 screws Take care of the EMC seal in the front grill

10 Remount and securely close the flap of the door trap system with the snap catches on the outside of the shelter.

NOTE: The trap door itself, without the ACU (but with the door/flap fitted), does not provide “Land Class C” attenuation, according to DEF-STAN-59-411

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Starting up and shutting down the air conditioner

Warning Cycling the temperature dial up and down rapidly will cause the cooling circuit not to start. This is due to a start up delay of the compressor built in to the controller.

Before starting up Before starting the AC M5W, the unit has to be brought into the deployed position. Fol-low this procedure:

Step Action

1 Release the two snap catches on the outside of the shelter, which are hold-ing the flap of the trap door system in place. If installed unhook the locking pin from the centre of the door/flap

2 Release the two hand screws at the side of the horn

Now the unit can be pushed out and secured with the set of snap catches

3 Park the two hand screws in the threaded insert in the front grill with the unit deployed.

The positions for hand screws, left to right: (the tip of the horn to the base) 1) Transport position. Hole at the

end of horns. 2) Filter change/service position.

(Large hole) 3) Parking spot when unit is opera-

tion (Obround hole)

Start up With the preplanning complete, the air conditioner is ready for operation: Follow the procedure below to start up the air conditioner:

Step Action

1 Turn the function switch to the desired mode (see “Description of the control board”, page 12) and the unit will operate according to the “Functional de-scription”, page 15 if not switched off by a safety device.

Fault If the unit does not operate it might have been switched off by a safety device: • HP pressure sensitive switch:

An ambient temperature higher than the working range 20°C-60°C will cause the condenser not to be cooled enough, resulting in excessive pressure in the cooling circuit and thereby a cut out by the HP pressure sensitive switch.

A reduced airflow through the condenser core can result in cut-out of the high pres-sure (HP).

• Evaporator or condenser fan thermo relay: Running current for the fan motor is too high

Continued overleaf

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Starting up and shutting down the air conditioner, continued

Fault, continued • Compressor thermo relay: Running current for the compressor is too high

• OT thermostat (only in models with heating installed): High air temperature, or non-operating evaporator fan has stopped the heating coil

Refer to the “Fault finding guide”, page 33 for possible solutions.

Shutting down Follow this procedure to shut down the air conditioner from any mode of operation:

Step Action

1 Turn the function toggle switch to OFF Result: All operations stop instantly

Warning: The evaporator fan will continue to operate, or start up, even with the function switch in zero position, if the temperature inside the ACU ex-ceeds 50 °C. The fan stops, with the function switch in zero position, as soon as the tem-perature drops below 35 °C

2 Release the two snap catches and unscrew the two hand screws, from their parking position and pull the unit back into the container

3 Secure the door of the trap door system by means of the two snap locks on the outside of the shelter and secure the ACU by the two hand screws at the tip of the horns. If the shelter is to be transported under slung by helicopter, mounting the safety pin of the trap door system is mandatory.

4 Disconnect the power cable at the power supply and coil the cable if: • the air conditioner is put aside for a longer period or • if service is to be performed

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Transport and lifting of the unit

Transport of the unit

The units are delivered, stacked and strapped to a pallet. Stack maximum 3 on a euro pallet. DO NOT STACK OTHERWISE

Lifting of the unit By means of a forklift is possible to lift the unit to the right height and to push it into the trap door system from the outside of the container. Note that this is only possible with the front grill assembly detached.

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Service guide Overview

Serial numbers This section gives the necessary information to help the responsible maintenance per-sonnel at servicing and repairing the air conditioner. All requests for information, service or parts should include the serial number. Product model and serial numbers are available from the data plate which is located on the right side of the unit.

Contents This section covers the following topics:

Topic See page

Preventive maintenance 26

Spare parts 29

Fault finding guide 33

Service agreement 35

26

Preventive maintenance

Introduction In order to achieve the best possible operation and long lifetime of the air conditioner it has to be maintained properly within defined guide lines. This section contains the description of daily, monthly and annual maintenance.

Tools For service and maintenance a torx 15 screwdriver and a 10 mm spanner or socket wrench is required.

CAUTION Before doing any maintenance, be sure that the air conditioner has been shut down and that the power cable is disconnected from the power supply. See section “Starting up and shutting down the air conditioner”, page 22.

Recommendations In addition to the preventive maintenance it is recommended to have a cooling techni-cian check the cooling circuit and all electrical functions. This check must follow the national rules for control of cooling equipment.

Daily preventive maintenance

Preventive maintenance to done on a daily basis or every 8 hours of operation: Perform the following preventive maintenance procedures each day or after every eight hours of operation:

Step Action

1 Inspect the power cable for damage or loose connections

2 Inspect the air filter and remove any debris or foreign objects that may have accumulated on the filter

Continued overleaf

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Preventive maintenance, continued

Monthly preven-tive maintenance

Please follow this procedure to do monthly preventive maintenance or every 200 hours of operation: Caution When dismounting the front cover you are breaking the EMC seal. When remounting the unit be aware that the EMC seal is intact and restored properly.

Step Action

1 Perform daily maintenance

2 Clean the air filter with a hoover or wash it in luke warm soap water. See the drawing below and follow the steps to get access to the filter

3 Loosen the two latches in each side of the unit

4 Grab the handles (one in each side) and pull the unit into the container

5 Fasten the screws (one in each side) to fix the unit

6 Dismount the front frame by unscrewing 16 torx 21 screws to get access to the filter

7 Grap the filter behind the frame and clean it with a hoover or wash in luke warm soap water

8 Check that the condensate drain is not blocked. Use high pressure air from the outside of the unit for 5 seconds to remove dirt. Condensate drain pipe

9 Follow the above steps just in reverse order to remount the unit Make sure that the filters are dry before they return to service again and are subjected to dust

Continued overleaf

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Preventive maintenance, continued

Annual preventive maintenance

Follow this procedure to carry out the annual preventive maintenance: Caution When dismounting the front and the top cover you are breaking the EMC seal. When remounting the unit be aware that the EMC seal is intact and restored properly.

Step Action

1 Perform the daily and monthly maintenance, see above

2 Place the unit on a surface where the front frame can be free

3 Inspect the evaporator and condenser coils. See the drawing below and follow the following steps to make access to the coils:

4 Dismount the front frame by unscrewing 16 torx 20 screws to get access

to the filter

5 Dismount all 21 screws on the top cover , top, sides and back

6 Inspect the evaporator and condenser coils. If they are dirty, then clean with a hoover or wash with warm soap water and a brush Lift up the internal fan module 7-10 cm to get better access to the evaporatorBefore being able to lift the fan module you need to unscrew 2 screws be-tween the fan house and the coils

7 Clean the drip tray

8 Inspect and if necessary clean the radial wheels in the two fans

9 Follow the above steps just in reverse order to remount the unit

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Spare parts

Introduction This section contains the general information needed when ordering spare parts. For units in military services spares will normally be ordered through the military logistic system. The spare parts lists are available on the following pages.

When ordering When ordering, kindly inform us about: • Dantherm Air Handling A/S spare parts number/text • NATO stock number of parts • Dantherm Air Handling A/S field unit type • Dantherm Air Handling A/S production and serial number from the data plate of the

field unit (or approximate date of delivery).

Information Not every item will be available for delivery individually, if it is part of a group naturally forming a whole or part of a purchased, complete component. Dantherm Air Handling A/S reserves the right to make this assessment.

Reservations Dantherm Air Handling A/S reserves the right to make any necessary changes of con-struction and choices of components without notice - but will, as far as possible, main-tain a stock of the changed parts.

Continued overleaf

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Spare parts, continued

Illustration Available spare parts for the Spare parts:

Fig. 2

Continued overleaf

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Spare parts, continued

List List of spare parts for the Spare parts:

Index No. Part No. Nomenclature NATO No.

1 063108 Cover complete with insulation 1670-22-620-0246 2 063109 Evaporator coil 4130-22-620-0248 3 066668 Heating 2000 W complete 4520-22-620-0249

4 063111 Fan and fan housing complete, evaporator

4120-22-620-0312

5 063112 Fan, evaporator 4140-22-620-0250 6 063113 Drip tray with drain tube components 9999-22-620-0251 7 063114 Handle, set with 2 pcs. 5340-22-620-0253 8 063115 Grill, internal side 5340-22-620-0256 9 063116 Front gable, complete 5340-22-620-0255 10 063117 Filter 4130-22-620-0257 11 063118 Base plate, complete 1670-22-620-0259

12 063119 Fan and fan housing complete, condenser

4140-22-620-0261

13 063120 Fan, condenser 4140-22-620-0263 14 063121 Condenser coil 4130-22-620-0265 15 063122 Sensor, set with 2 pcs. 6685-22-620-0266 16 063123 Inspection glass 6680-22-620-0316 17 063124 Expansion valve 4820-22-620-0267 18 063125 Service valve 4820-22-620-0268 19 063126 Switch, high pressure 5930-22-620-0270 20 063127 Compressor 4130-22-620-0271 21 063128 Receiver 4130-22-620-0272 22 063129 Dry filter 4130-22-620-0273 23 063130 Control box complete 4130-22-620-0274 24 063131 Capacitor 5µF 5910-22-620-0275 25 063132 Capacitor 40µF 5910-22-620-0276 26 063133 Capacitor 2,5µF 5910-22-620-0277

27 063134 Front label, cable entry, switches and potentiometer

5975-22-620-0278

28 063135 Control box bottom 6110-22-620-0279 29 063136 Rubber grommet set 5365-22-620-0280

Continued overleaf

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Spare parts, continued

List, continued Index No. Part No. Nomenclature NATO No.

30 063137 Control, printed circuit board 5998-22-620-0281 31 063138 Control box, cover 5340-22-620-0282 32 063139 Copper tube set 4710-22-620-0296 33 063140 EMC seal complete, 2 pcs. 4120-22-620-0311

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Fault finding guide

Fault finding Malfunctions that might occur in the operation of the air conditioner are listed in the ta-ble below. Reference to actions required to restore the air conditioner to normal operat-ing condition are also indicated. If the air conditioner should malfunction, find the problem in column 1. Columns 2 and 3 describe the possible causes and corrective actions. The list of problems, causes, and remedies will only give an indication of where a possible problem can be and what ac-tions are needed to correct the problem. Problems, which are caused by electrical faults or related to the cooling plant, have to be corrected by skilled personnel

Problem Cause Action

The unit does not oper-ate. The power indicator lamp on the control panel is not ON

No power input Check that the power ca-ble is correctly connected to power source and unit Check that power source is turned on and providing 1 × 230 V AC

Air conditioner does not operate. Power indicator lamp is green. Cool light is green and turns yellow

High ambient temperature resulting in HP pressure sensitive switch cut-out (automatic reset) or low pressure conditions are de-tected

Check the condenser side for sufficient air flow. Be sure that no air path is blocked

The evaporator is blocked with ice. This will auto re-set in time.

Yellow light means the unit is operated ineffi-ciently

Cooling circuit only oper-ates a very short time be-fore HP/LP pressure sen-sitive switch cut-out

Power indicator lamp is green

Cool light is green and turns yellow.

Ambient temperature is not within working range 20 °C – 60 °C

Wait until ambient tem-perature is within working range. Allow the unit to cool down (10-15 min.)

Air conditioner operates - but no cooling. The power indicator lamp is green. Cooling lamp is red

Refrigerant leak. Internal temperature protec-tion compressor has cut-out. Faulty compressor

Call an air condition ser-vice technician

Continued overleaf

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Fault finding guide, continued

Fault finding, con-tinued

Problem Cause Action

No heating action possi-ble.

Power light is green.

Heat indicator lamp is red.

Overheat thermostat failure or loose electrical connec-tion

Allow temperature to drop before pressing the reset button on top of ACU

Fans stop running. Fan light is red

Internal temperature protec-tion in either condenser or evaporator fan motor has cut-out

Check for blocked fan(s). Check for loose connec-tors

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Service agreement

Introduction The unit includes mechanical and electrical parts and the unit is often placed in a rough environment where the components are exposed to different climate conditions. There-fore the unit will need preventative maintenance on a regular basis.

Hotline The After Sales Support Department of Dantherm Air Handling A/S is ready to help you in case of a problem. To be able to offer quick and efficient help, please have the following information ready when contacting Dantherm Air Handling A/S:

• Name • Company • Country

• Phone no. • Email • Type (unit)

• Site/location (unit) • Serial no/order no. • Description of the problem

Contact Dantherm Air Handling A/S, ask for the After Sales Support department and help will be provided as soon as possible:

Phone: +45 96 14 37 00 Fax: +45 96 14 38 00 Email: [email protected]

Preventive main-tenance

Dantherm Air Handling A/S offers to do the preventive maintenance on the units so thatthey at all times will operate according to factory standards.

Corrective and emergency repair

In case of malfunctions of the product Dantherm Air Handling A/S offers to do emer-gency repair on the climate units. Agreements will be made with the customer on re-sponse time and price.

Setup Dantherm Air Handling A/S has established a network of service partners to do the pre-ventative maintenance. The partner is trained and certified on the actual climate units. The partner will also carry an adequate number of spare parts – so that any repairs can be made during the same visit. The agreement will be made with Dantherm Air Handling A/S – and the overall respon-sibility for the agreement will be Dantherm Air Handling A/S’s.

Further informa-tion

For further information about a service agreement in your country or region, please con-tact:

Henrik Hersted After Sales Support Manager Dantherm Air Handling A/S Phone: +45 9614 4767 Mobile: +45 2399 4066 Email: [email protected]

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Technical information Overview

Contents This section covers the following topics:

Topic See page

Technical data 37

Dimensions 38

Wiring diagram 39

References for the wiring diagram 41

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Technical data

Introduction Technical data for the AC-M5 W MKII unit.

Performance characteristics

The air conditioner has a maximum cooling capacity of 4.7 kW. When the relative humidity of the air inlet is high, the air can be cooled below its dew point and thus condense some of the water vapour to free water. This requires a certain amount of latent cooling but provides a dehumidification process, which is an important factor in comfortable air supply conditions. The operating range is between 20 and 60 °C approximately and is controlled by the HP-pressure switch. In relatively dry locations the air temperature drop will depend on inlet conditions.

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

Specification Value

Voltage/PH/frequency 230 V 1 PH/50 Hz

Electric consumption, max. 2.4 kW/11.2 A

Cooling capacity, max. 4.7 kW

Heating capacity (option) 2.0 kW/8.6 A

Airflow low, evaporator 420 m³/h

Airflow high, evaporator 900 m³/h

Airflow, condenser 1475 m³/h

Refrigerant/Load R134a/1.4 kg

Max. refrigerant pressure 28 Bar

Operation temp. range 20-60 °C

Weight 79 kg

Noise level (1 m) low speed 49/48*) dB(A)

Noise level (1 m) high speed 64/63.5*) dB(A)

*) With/without compressor active

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Dimensions

Illustration This illustrates the unit dimensions (mm):

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Wiring diagram

Wiring diagram, a This is the wiring diagram for the unit, references are available on page 41:

Continued overleaf

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Wiring diagram, continued

Wiring diagram, b

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References for the wiring diagram

References The references refer to the wiring diagram:

Reference Description

E1 Electrical heat 2x1000 W/230 V

M1 Compressor ZR 22 K3E-PFJ

R1 RC unit 470n + 47R X2

C1 Capacitor for compressor 40 MF/400 V

M2 Condenser fan EBM A4E350

C2 Capacitor for condenser fan

M3 Condensate pump Blue Diamond*)

C4 Capacitor for evaporator fan 5mF/450 V low speed

M4 Evaporator fan EBM R4E280

C3 Capacitor for evaporator fan 2,5 mF/450 V

R2 Limit air temperature sensor heat/fan

R3 Return air temperature sensor

S1 Test button (only for service)

B2 High pressure switch with auto reset

S2 Fan speed selector high-low

S3 Temperature set point

S4 Function selector Auto-Off-Fan

*) Option