Dantherm VA-M40 MKII User manual

1
971145 •Version 2.1 • 22.10.2012
VA-M40 MKII
Service manual
Rev. 2.2
en

2
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

3
971145 •Version 2.1 • 22.10.2012
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 effi-
cient service.
This is the service manual for the Dantherm VA-M40 MK II unit.
Models
This manual covers for the following models:
Dantherm number
Code
NATO stock number
322017
VA-M40-B-225-RXXXX
-
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.
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
See page
Introduction
3
Safety and warning instructions
4
General information
7
Syntax
8
Product description
9
User’s guide
20
Service guide
34
Technical information
82
Index
87

4
Safety and warning instructions
Introduction
Safety must always be the operator's prime concern. The operator must read and under-
stand 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 per-
sonal 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. Nev-
er 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 in-
take 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

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971145 •Version 2.1 • 22.10.2012
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 can-
not be detected and eliminated the heater combustion chamber must be inspected for
cracks or other defects.
Warning,
electrical hazards
Electrical shock
This heater, and its associated thermostat, operates at 1 × 230 V AC; 50 Hz and conse-
quently 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 recti-
fied immediately.
Earthing
This heater must be earthed through the 3-core electrical supply cable.
Warning
handling and use
of fuel
Handling of fuel
Fuel is a hazardous substance. Refueling operations must take place in well ventilated
areas, away from sources of ignition. Refer to relevant safety data sheetsand COSHH as-
sessments. 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 transporta-
tion, 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 ab-
sorbent material disposed of. Do not let hot heater surfaces come into contact with
items which could readily ignite.
Continued overleaf

6
Safety and warning instructions, continued
Warning
location and ex-
haust fumes
Location
Never operate the heater in a confined space without adequate ventilation. The heater
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 ex-
haust 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 in-
spected 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,
physical handling
Lifting and movement
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 Me-
chanical Handling Equipment (MHE) or by sufficient numbers of personnel correctly lo-
cated 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
Do not disconnect the power until the air supply fan has completely stopped.

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971145 •Version 2.1 • 22.10.2012
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 permis-
sion 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
Conformity
Dantherm, Marienlystvej 65, DK-7800 Skive hereby declares that the:
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 re-
cycled, the unit should be recycled according to national rules and procedures to pro-
tect the environment.

8
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 Four digit RAL colour code
X Specifics/custom

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971145 •Version 2.1 • 22.10.2012
Product description
Overview
Introduction
This section will give a more detailed description of the VA-M40 MK II and its function-
ality.
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
General description
10
Cabinet
11
Combustion system
13
Air circulation system
14
Fuel system
15
Control system
16
Accessories
19

10
General description
Purpose and field
applications
The Dantherm portable, duct type, heater model VA-M40 MK II is designed primarily to
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 com-
bustion products or fumes are introduced into the occupied spaces. The forced air sys-
tem provides the most rapid of warm-up capabilities. The units are essentially self-
contained requiring only a source of external electric power.
Performance char-
acteristics
The heater has a maximum heat output of 38 kW with a minimum combustion efficiency
of 85 %. The unit will start at temperatures as low as - 40 °C, and is factory set for oper-
ation to an altitude of 1,500 m Operation at higher altitudes requires minor field ad-
justment of the oil burner. The protective cabinet allows operation in snow or rainy con-
ditions.
Set up and opera-
tion
Set up and operation can be done by a single person. After start up, the heater functions
are automatic, thus permitting the item to be left unattended between periods of refuel-
ing. An optional remote thermostat may be connected to the heater for accurate tem-
perature 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
parts
All critical sub-systems and component assemblies are replaceable as modular kits; this
ensures a repair capability at Unit level. No special tools are required for module re-
placement.
Standard configu-
ration
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

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971145 •Version 2.1 • 22.10.2012
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:
Fig. 1
No.
Part

Outlet openings

Flue stack

Access holes for wheel stor-
age

Storage compartment

Flue outlet opening

Adjustable fresh air open-
ings

Wheels

Skids

Parking stand

Hinged door
Inlet openings
Wheels
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 hori-
zontal position when the wheels are removed.
Lifting and carry-
ing
Manual lifting and transporting the unit is carried out by the use of the side handrails,
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-
ment
When not in use, the remote thermostat (accessory), CO monitor (accessory), tool kit,
service manual, and wheels are stored within the storage compartment at the rear of
the heater.
Burner compart-
ment, service ac-
cess
The hinged door at the front of the unit gives complete access to the burner com-
partment which houses the oil burner, electrical controls, fuel systems and filter.
At the same time it is the storage room for the power supply cable under transport.
Continued overleaf











1
1
1
1

12
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. (Re-
circulation 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-
ings
The flue outlet opening can be closed by a cover, when not in use which is designed
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 stor-
age purposes the flue stack is placed on brackets along the cabinet side.

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971145 •Version 2.1 • 22.10.2012
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:
Fig. 2
No.
Part

Flue stack

Heat exchanger

Inspection glass

Oil burner
*
Combustion sys-
tem
This system consists of an oil burner , combustion chamber with heat exchanger ,
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 com-
bustion air and atomized fuel will create a sort of gas which gives high efficiency com-
bustion 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 con-
trolled by a solid-state electronic device. During start up a 15 second pre-purge is fol-
lowed by the opening of the solenoid valve for oil atomizing and ignition. Safety shut-
down 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
sealed construction which prevents the combustion gases from escaping into the air cir-
culation 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 approxi-
mately 2 m above ground.





14
Air circulation system
Illustration
This illustrates the air circulation system:
Fig. 3
No.
Part

Heated air outlet

Direct driven fan

Air inlet

Fresh air intake
Air circulation sys-
tem
The air circulation system consists of a direct driven fan and internal air passages
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.





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971145 •Version 2.1 • 22.10.2012
Fuel system
Illustration
This illustrates the fuel system:
Fig. 4
No.
Part

Fuel pump

Flow control/De-
Aerator

Fuel pre-heater

Filter/water separa-
tor

Oil lance
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 con-
stant 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 pre-
heater 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
contains the last fine filter in this system.






16
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 trou-
bleshooting.
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:
Fig. 5
No.
Part

Connector for remote thermostat

Connector for CO monitoring

Function switch
See details on the different posi-
tions in section “Operation of the
heater”, page 27

Power supply cable
Illustration, inside
This illustrates the control panel which it is possible to see on the left hand side, after
opening the burner compartment cover:
Fig. 6
No.
Part

LED lights which indicate the dif-
ferent 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
Continued overleaf








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971145 •Version 2.1 • 22.10.2012
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 distribu-
tion duct. The CO monitor is factory set and will stop the complete unit if the CO con-
tent 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
thermostat
The internal fan thermostat control delays fan operation until the discharge air tem-
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 tempera-
ture. After the burner stopped the fan will continue to operate and cool the heat ex-
changer/combustion chamber until the air discharge temperature has fallen to approx-
imately 30 °C.
The limit thermostat automatically stops the burner if the air discharge temperature ex-
ceeds 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-
tion
The overheat thermostat operates when the heat exchanger is in danger of being dam-
aged from an excess of temperature. This thermostat protector shuts down the fuel, ig-
nition and air supply systems. The red OT indicator lamp on the internal control box il-
luminates.
Follow this procedure to reset the system (after determining the fault):
Burner flameout
protection
A flameout protector built in into the burner, activates when the burner flame is abnor-
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:
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

18
Control system, continued
, continued
LED
Color
Indication
CO failure
Red
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
Green
Illuminates when the power is connected to the unit
Reset circuit
breaker
For protection of control circuit this breaker is installed. If it trips off, the breaker has to
be reset by pressing the button.
Hour meter
This hour meter accumulates the hours the burner is active.

19
971145 •Version 2.1 • 22.10.2012
Accessories
Introduction
There are different accessories available for the VA-M40 MK II which can be ordered di-
rectly 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
insulated air duct
Remote thermo-
stat
Insulated air duct
3 m
CO monitor
Air distribution
duct 5 m
Dry powder ex-
tinguisher
Jerry can
Oil lance for jerry
can

20
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
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