Dantherm KONTROLLELEKTRONIK EFC2 V2 TC User manual

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EFC2 V2 TC
Service manual

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Introduction
Overview This is the service manual for the Free Cooling unit EFC2 V2 TC with air inlet at the
bottom, a compact F5-filter and two high flow fans. Furthermore the Free Cooling unit
has an air intake damper and an advanced controlling unit.
Table of contents EFC2 V2 TC ...............................................................................................1
Introduction.................................................................................................2
General information....................................................................................3
Technical data ............................................................................................4
Dimensions.................................................................................................6
Functional description.................................................................................7
Wiring diagram – TKS 3000........................................................................8
Wiring diagram – ACUE CS1......................................................................9
Preventive maintenance...........................................................................10
Spare parts list..........................................................................................11
Test Report: TKS 3000 and ACUE 3000..................................................12
Test Report: ACUE CS1...........................................................................14
Contact In the table below you can see how to contact the manufacturer and sales offices.
Office Sweden Norway Denmark
Name Kontrollelektronik
Dantherm Air Handling AB A/S Dantherm avd. Kontrollelektronik Dantherm Air Handling A/S
Address Virkesgatan 5 Postboks 147 /
Storgatan 29 Marienlystvej 65
SE-614 31 Söderköping
Sweden NO-1851 Mysen Norway DK-7800 Skive Denmark
Phone [phone] [phone] [phone]
Fax [phone] [phone] [phone]
E-mail [email protected] dantherm.n[email protected] [e-mail]
Web kontrollelektronik.com www.dantherm.no www.dantherm.com

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General information
Introduction This section gives you the general information about the unit and this service manual.
Target group The target group of this service manual is the technicians who install and maintain the
unit.
Copyright Copying of this service manual, or part of it, is not allowed without written permission
from Kontrollelektronik Dantherm Air Handling AB.
Reservations The service manual is subject to changes without notice.
CE-Declaration of
Conformity Kontrollelektronik Dantherm Air Handling AB, Virkesgatan 5, SE-614 31 Söderköping
hereby declare that the unit are in conformity with the following directives:
2006/95/EG Low Voltage Directive including 93/68/EEC where required
86/336 EEC EMC Directive including 92/31/EEC and 93/68/EEC
89/392 EEC Machine Directive
The product is manufactured according to SS-EN 604 39-1
The product is manufactured with components which follow the application standards
for Low Voltage Directive and in case of norms for EMC in EU countries.
The product is controlled and tested before delivery according to the following:
Real test of built in functions with connected temperature sensors and
damper actuators.
Inspection of labeling and marking.
Ocular inspection of mounted materials and electrical connections.
Inspection that all parameter and settings are set to delivery position.
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 producers to
protect the environment.

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Technical data
Free Cooling
Performance The table below shows the performance of the Free cooling unit:
Specification 48V DC 230V AC
Air flow (at 53 V DC) 622 l/s (2240m3/h) 700 l/s (2520m3/h)
Free cooling capacity 746 W/K 830 W/K
Free cooling capacity at Δt=7°C 5,2 kW 5,8 kW
Power consumption 210 W 270 W
Sound pressure at 3m from shelter Approx. 37dBA Approx. 37dBA
External available pressure drop 50 Pa 50 Pa
Dimensions (WxHxD) 650x650x650 650x650x650
Dimensions with frame (WxHxD) 720x720x656 720x720x656
Cabinet data Data and dimensions of the cabinet are shown in the following table:
Specification Designation Value
Weight Estimated to max 45 kg
Metal sheet material Aluzinc AZ150 0,9-2,0 mm
Frame material Aluminium 1,5 mm (minimum thickness)
Exterior panel coating Pre-varnished zinc-
coated steel (medium
blue colour RAL 5024)
0,5 mm
Interior panel coating Zinc-coated steel 0,5 mm
Panel insulation Expanded
polyurethane 25 mm
Fan motor data Data of the fan motor is shown in the following table:
Specification 48V DC 230V AC
Voltage nominal 48V DC 230V AC
Current 2x2,6 A 2x0,59 A
Power consumption 2x105 W 2x135 W
Speed 2750 rpm 2550 rpm
Continued overleaf

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Technical data, continued
Filter data In the table below the data of the filter are specified:
Specification Compact filter
Type Compact filter
Removal efficiency F5
Dimensions 540 x 548 x 130 mm
Total Area 10,5 m2
Filter monitor setting 130 Pa
Controlling The table below show the components and types for controlling of the Free cooling unit:
Specification 48 VDC 48V DC 230V AC
Control unit
(See separate manual) ACUE CSI 3GS ACUE 3000 TKS 3000
Indoor temperature
sensor RG-K81 RG-TD5A RG-TD5A
Filter monitor JDW5 JDW5 JDW5
Damper data In the table below the motorized damper and actuator are specified:
Specification TC 48V TC 230V
Type SP470x511 SP470x511
Dimensions (WxH) 470x511 470x511
Actuator type LM24 A (24V DC) LM230 A (230V AC)

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Dimensions
Illustration This drawing illustrates the dimensions of the Free cooling unit:
FRONTVIEW WITH FRAME
BOTTOM OF UNIT WITH AIR INTAKE GRILL
WALL
FRAME
DRIFTSTATUS
INDOORTEMPERATURE
SETMOTOR PROTECTOR
SETCOOLINGUNITS(0-1-2)
SETH IGH TEMP. ALARM
SET CONTROL MODE
SETLOW TE MP. ALARM
OUTDOOR TEMPERATURE
SETTEMP. EL. HEATER
SETDIFF. TEMP.COOLING 1
SETDIFF. TEMP.COOLING 2
MODESETTING
SETMAX. FAN SPEED
SETDIFF. TEMP . FAN
SETINDOORTEMP.
ALARM
HIGHTEMP.
LOWTEMP.
ÓN
FAN
ELHEATER
TIMER
FAN
RESET
COOLING
FILTER
FAN
TEMPERATURE CONTROLLER
TKS 3000
FILE: EFC2 V2 TC 230 TKS 3000
SLOPE 10 mm
SIDE VIEW
WALL

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Functional description
Flow The picture below schematically shows the air flow in a shelter. In the same picture some
accessories that can be connected to the controller are shown.
GT1
EFC2 V2 230 V
RADIOBASE SHELTER
GT2
ELECTRICAL HEATER RC
230V AC
TKS 3000
ST3
ST1
GP
(ACCESSORY
f

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Wiring diagram – TKS 3000
2 Brown
3 White
1 Blue
Outdoor temp. Sensor (SG-TD5A)
Filter monitor
GP1
White
Brown
3 2
White
Brown
White
Brown
Junction Box
EFC2 V2 TC 230
Fan motor
TC
Fan motor
External
connection to MC
Brown
White
Green
Brown
White
5 6
7
8
2
1
Y/G
4
3
Yellow/green
Brown Blue
Brown Blue
Yellow/green
L
N PE
Main supplye
230 VAC
10A
Electrical Heater
230 VAC Max 6A
PE N LBrown
Blue
Yellow/green
Brown Blue
Yellow/green
Brown
White Indoor temp sensor
(RG-TD5A)
Exhaust
Air damper 230VAC
LM230A
3 x 0,5
Brown
Green
White
2 Brown
3 White
1 Blue
Junction box
Brown
Green
White
Filter Alarm Output Fan Alarm Output
Low Temp Alarm Output High Temp Alarm Output
1
3
5
2
3 x 1,5 3 x 1,5
2
1
3
4
Y/G
5 6
7
8
Green
White
Brown
11
14 12
A2 A1
L N PE L N PE
Brown Brown Blue Blue
Y/G
Exhaust
Air damper 230VAC
LM230A
PE
V1 V2
PE
L
N PE EN EL PE
C11 C12
Y2
COM
Y1
COM
TK1 TK2 TK3 TK4
COM
D11 D12 D13 D21 D22 D23
SLX
COM
Fir
COM
Fil
COM COM
FiA
COM
FaA
COM
LTA
COM
HTA
TKS 3000
600-23771610
RS-232
NC
NO
TKS 3000 EFC2 V2 TC 080515
RT
OT
COM
Int fuse 5AT

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Wiring diagram – ACUE CS1
D32
D22
BATTERYSUPPLY48VDC
RS232
DATACOM
2
11
2
SD+
SD-
HIGHTEMPALARMOUTPUT
LOWTEMPALARMOUTPUT
ACUE-CS1
600-23471210
K040330
REV.R1A
CONTROLUNIT
2x0.5INDOORTEMP.
FILTERMONITOR
FAN48VDC*
=INTERNALINSTALLATION
10AFUSE
BATTERYSUPPLYUNIT
3
2
1
2
4
3
Line/Heatersupplyvoltage(2m)
Indoortemp.sensor(1,5m)
Batterysupply(1,5m)
Notinuse
Exhaustairdamper(6,5m)
5
Brown
Blue
D12
D31
D21
D11
ML
Y1
+VS
+48
-48
Brown
Blue
Y1
PB1
M2
GT1
M1
GT2
F11
PLC
M3
SD1
SD2
-VS
N
C21
C22
PE
C11
PE
C12
E2
E1
L
PE
PE
4
5 3
3G1,5
1
L
N3
23G1,5
JUNCTIONBOX
Green/yellow
White
3
5
4Brown
1
2Black
Blue
5G1,5
1
Black
Blue
Green/yellow
White
Brown
PB2
F12
Brown
White
Brown
WhiteSENSOR(RG-K81)
PUSHBUTTON
TIMER(OPTION)
2x0.5
OUTDOORTEMP.
SENSOR(SG-K81)
White
Brown
3
2
Fno
Fnc
F-c
M-c
Mnc
Mno
Hno
Hnc
H-c
Lno
Lnc
L-c
SQ1
SQ2
2
12
1
1
21
2
FILTERALARMOUTPUT
MOTORALARMOUTPUT
3
4
2
1
4
3
2
1
2x1,5
2x0.5
2x0.5
4x0.5
GT1
GT2
GP1
PB1
+
-
- +
Y1
ML
+
-
Y1
ML
ML
Y1
-
+
ML
Y1
-
+
3
2
1
1
2
3
4
5
6
7
White
Brown
Brown
White
EFC2V248VDC
ST3EXHAUST
AIRDAMPER
AIRDAMPER
ST1SUPPLY
White
Brown
Green
2
3
4
6
7
8
9
10
11
1
*
5
MAX2200W
FANCONTROL
LINE230V,50Hz
FUSEMAX10A
SUPPLYVOLTAGE
ELECTRICAL
FANHEATER
8
9
5
1
2
3
4
5
6
7
8
9
File:EFC2V2ACUE3GSEL4050704
SEEELECTRICAL
WIRINGPAGE2
3G-LARM,TERMINAL5
REMOVEJUMPER
Y2
Brown
White
Green
Green
Yellow
White
Brown
Green
JUNCTIONBOX
White3
White2
Black1
10
10

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Preventive maintenance
Introduction The unit needs preventive maintenance with specific intervals to avoid breakdown or
inefficient operation. It is important to notice that interval between maintenance can
vary depending on the specific environment.
Caution! Switch off the AC supply before working on the unit!
Make sure that all work has been performed before switching on the power again.
Service function
“Timer”
The controlling unit has a service function to ensure better indoor climate for 20
minutes during the presence of service technicians. To activate the service function,
push one step up from the main menu to find “Timer”. Now press “Enter”. The control
unit will now count down from 20 and then go back to normal operation.
Interval Kontrollelektronik Dantherm Air Handling AB recommends that intervals between
preventive maintenance do not exceed 1 year. It is also our recommendation that the
site and unit is examined closely during the first preventive maintenance to determine
whether the interval is too long. We recommend that preventive maintenance visits are
planned to occur in springtime.
Condition for
warranty The factory warranty is only valid if documented preventive maintenance has been
carried out with an interval of maximum 1 year. The documentation could be in form of
a written log.
Leaving the site Before leaving the site, make sure there are no alarms!
Recommended
approach The recommended approach when performing a preventive maintenance visit is:
Step Action
1 Make sure that the power to the unit is safely switched off.
2 Remove the worn-out filter and clean the unit carefully.
3 Clean the dampers and check them regarding function and tightness.
4 Clean the fan and check its mounting.
5 Check and clean the air intake and exhaust accessories.
6 Insert the new filter carefully into the unit.
7 Close the unit and make sure that the service is completed correctly.
8 Turn on the power to the unit.
9 Run the Self test according to the separate manual for the controller.
Function tests Fan and filter alarm function tests can be done by the following actions.
Function test Action
Filter Open the service door and put a plate of carton or similar on the
intake side of the filter, blocking a big part of the filter area. Close the
service door, run the free cooling unit and check that filter alarm is
given. Stop and remove the plate.
Fan Open the lid to the controlling unit and remove the brown cable
connected to the connector marked “TK1”. Close the lid, run the free
cooling unit and check that fan alarm is given. Restore the controller.

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Spare parts list
List Below are the complete list of spare parts with part numbers:
Spare part Type Part number
Compact filter F5, 540 x 548 x 130 mm 900-07605482
Fan 230V 023-92184844
Fan 48V 023-92184831
Control Unit 230V TKS 3000 600-23771610
Control Unit 48V ACUE 3000 600-23671410
Control Unit 48V ACUE CSI 3GS 600-23471210
Indoor temp. sensor RG-TD5A 720-112420
Indoor temp. sensor RG-K81 720-110524
Filter monitor JDW5 021-422314
Damper actuator LM230 889-331570
Damper actuator LM24 889-331562
Contact In the table below you can see how to contact the manufacturer and sales offices.
Office Sweden Norway Denmark
Name Kontrollelektronik
Dantherm Air Handling AB A/S Dantherm avd. Kontrollelektronik Dantherm Air Handling A/S
Address Virkesgatan 5 Postboks 147 /
Storgatan 29 Marienlystvej 65
SE-614 31 Söderköping
Sweden NO-1851 Mysen Norway DK-7800 Skive Denmark
Phone [phone] [phone] [phone]
Fax [phone] [phone] [phone]
E-mail [email protected] dantherm.n[email protected] [e-mail]
Web kontrollelektronik.com www.dantherm.no www.dantherm.com

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Test Report: TKS 3000 and ACUE 3000
Introduction After electrical installation of the free air cooling unit, the display normally shows actual
room temperature (if indication is at Indoor temp).
The following tests shall be done to secure the function of the system. Every
checkpoint shall be receipted with a sign and finally a date. This is to secure and
document the guarantee and future service.
Observe: Check that there is no protection paper blocking the filter before starting up. If
there is, no air flow will come and you will get a filter alarm.
Start a test To start a new test you push two steps up from the main menu to find “Self Test”. Now
push “Enter”. The control unit will now execute the Self test according to the schedule
below.
Test performance Test phase Time (s) Action Check
1 60 Heater activated (if installed).
Check that the heater becomes warm.
2 120 Air dampers to environment open (if installed).
Check that the air damper opens.
3 60 Fan signal speed up to max.
Check that the fan speed up to max speed.
4 120 TC-function active (if installed).
Fan signal is reduced to min. speed.
Check that the fan speed is reduced. Check
that the TC-damper opens alternative one of
the fans are stopped.
5 60 AC unit active (if installed), fan is stopped.
Check that the Active Cooling unit starts.
6 10 Relay output Filter alarm active.
On the connector (if installed) check that the
circuit is closed (/or opened).
7 10 Relay output summary alarm fans active.
On the connector (if installed) check that the
circuit is closed (/or opened).
8 10 Relay output Low temp. alarm active.
On the connector (if installed) check that the
circuit is closed (/or opened).
9 10 Relay output High temp. alarm active.
On the connector (if installed) check that the
circuit are closed (/or opened).
10 10 Room sensor tested.
Observe the display.
11 10 Outdoor sensor tested.
Observe the display.

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Test Report: TKS 3000 and ACUE 3000, continued
Fire & smoke alarm After the self test, the Fire and smoke alarm (if applicable) shall be done.
Alarm Action Check
Fire & smoke alarm Activate the smoke detector.
Check that everything is stopped: Fan, Heater,
AC, and that the dampers are closed. The display
shows “Fire Alarm”.
Sign the protocol Test report data
Site – station designation/no
Test date
Test made by
Signature
Company
Documentation Send a copy of the protocol to the responsible operator.

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Test Report: ACUE CS1
Introduction After electrical installation of the free air cooling unit, the display normally shows actual
room temperature (if indication is at Indoor temp).
The following tests shall be done to secure the function of the system. Every
checkpoint shall be receipted with a sign and finally a date. This is to secure and
document the guarantee and future service.
Observe: Check that there is no protection paper blocking the filter before starting up. If
there is, no air flow will come and you will get a filter alarm.
Start a test To initiate Self test following procedure must be done.
Press the push button “RESET MOTOR/TIMER” and hold it pressed until the display
shows a “0”. The control unit will now execute the self test after the schedule below.
By pressing the puch button agin you can do manual steps in the test without time
delay. The test can be stopped whenever you wish by pressing the button
approximately 5 seconds or until the display show any form of a two-figure number.
The designations in the protocol refer to the flow chart in the manual.
Test performance Test phase Time (s) Action Check
0 100 Heater activated.
Check that the heater becomes warm.
1 100 Air dampers to environment open.
Check that the air damper opens.
2 40 Fan signal speed up to max.
Check that the fan speed up to max speed.
3 100 TC-function active.
Fan signal is reduced to min. speed.
Check that the fan speed is reduced. Check
that the TC-damper opens alternative one of
the fans are stopped.
4 20 Test of Room temp. sensor GT1.
Observe the display (see next side).
5 20 Test of Outdoor temp. sensor GT2.
Observe the display (see next side).
6 20 Activation of Low temp. alarm.
Check the indication lamp Low temp.
7 20 Activation of High temp. alarm.
Check the indication lamp Low temp.
8 40 Cooling unit 1 active (if AC-UNITS = 1 or 2).
Check the AC-unit starts (if installed).
9 40 Cooling unit 2 active (if AC-UNITS = 2).
Check the AC-unit starts (if installed).

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Test Report: ACUE CS1, continued
Test of temperature
sensors
Fire & smoke alarm
If the display show a “-“ this means that the sensors is out of range. What the sensor
indicate, warm or cold,
indicates with the lamps LOW TEMP. ALARM respectively HIGH TEMP. ALARM
following:
LOW TEMP. ALARM: The sensor indicate very cold (short-circuit).
HIGH TEMP. ALARM: The sensor indicate very hot. (cut-off or not connected).
To make the test of the sensors as reliable as possible, please make no manual
steps.
After the self test, the Fire and smoke alarm (if applicable) shall be done.
Alarm Action Check
Fire & smoke alarm Activate the smoke detector.
Check that everything is stopped: Fan, Heater,
AC, and that the dampers are closed. The display
shows “Fire Alarm”.
Sign the protocol Test report data
Site – station designation/no
Test date
Test made by
Signature
Company
Documentation Send a copy of the protocol to the responsible operator.