Dantherm Silencio 600 User manual

Silencio
Service manual
EN
No. 018717 • ver. 1.1• 23.01.2007

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
018717 • Version 1.1 • 23.01.2007
Introduction
Overview
Introduction This is the service manual for the Dantherm Air Handling Silencio unit.
The table of content below gives you an overview of the main sections. Please see the
complete table of content for further information about the sections.
Table of content This service manual covers the following main topics:
Topic See page
Introduction this page
Table of content, complete next page
General information 6
Definitions 7
Product description 8
Get ready for use 23
Users guide 31
Service guide 32
Technical information 74

4
Table of content
Introduction This is the complete table of content covering all sections in this service manual.
Each main section will begin with an introduction including a separate table of content
covering the exact section.
Table of content This service manual covers the following topics:
Topic See page
Introduction next page
Table of content 4
General information 6
Definitions 7
Product description 8
General description 9
Description of parts 11
Description of the control board 14
Functional description 17
Set points 20
Control strategy 21
Get ready for use 23
Unwrapping 24
Mounting 25
Installation and starting 30
Users guide 31
Service guide 32
Preventive maintenance 33
Accessories 35
Spare parts 38
Spare parts list 39
How to replace the VDI filter 40
How to replace the internal fan 42
How to replace one of the external fans 44
How to replace the control board 46
How to replace the recycle timer for the external fans 48
How to replace the damper motor 50
How to replace the PPI filter 52
How to replace the heater element 54
How to replace the temperature sensors 56
Continued overleaf

5
018717 • Version 1.1 • 23.01.2007
Table of content, continued
Table of content,
continued
Topic See page
How to replace the compressor contactor 60
How to replace the heater contactor 62
How to replace the EPROM 64
How to replace the phase reversal monitor 66
How to replace the thermostat for the heating element 68
How to replace parts of the cooling system 70
Fault finding guide 71
Service agreement 73
Technical information 74
Technical data 75
Dimensions 79
Wiring diagram 80
Mains supply 81
Compressor control 82
Fan control 83
Heating control 84
DanCon control board 85

6
General information
Introduction This section gives you the general information about the unit and this service manual.
The service manual covers all the Silencio versions.
Silencio is available in 6, 8, 10 and 14 kW.
Manual, part
number Part number of this service manual is 018717.
Target group The target group for 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 Dantherm Air Handling A/S.
Reservations The service manual is subject to changes without notice.
CE-Declaration of
Conformity
Dantherm Air Handling A/S, Marienlystvej 65, DK-7800 Skive hereby declare that the
units mentioned below:
365006 Silencio 600 3 × 400 V AC, 50 Hz and 48 V DC
365008 Silencio 800 3 × 400 V AC, 50 Hz and 48 V DC
365010 Silencio 1000 3 × 400 V AC, 50 Hz and 48 V DC
365014 Silencio 1400 3 × 400 V AC, 50 Hz and 48 V DC
are 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
97/23/EEC The Pressure Equipment Directive
- and are manufactured in conformity with the following standards:
EN 292 Machine Safety
EN 60 335-1 Low voltage
EN 60 335-2 Low voltage
EN 60 000-6-2 Immunity
EN 60 000-6-3 Emission
Skive, 01.11.2004
Recycling The unit is designed to last for many years. When the time comes for the unit to be
recycled, the unit should be recycled according to national rules and procedures to
protect the environment.

7
018717 • Version 1.1 • 23.01.2007
Definitions
Introduction This section gives you a definition of some of the technical words and terms used in this
manual.
List Here you have the list of words and terms with the matching definition:
Term Definition
Return air (T1) Internal air entering the ACU
Ambient air (T2) External air entering the ACU
Exhaust air (T3) External air leaving the ACU
Supply air (T4) Internal air leaving the ACU
Cooling set point Cooling set point (the temperature at which the active
cooling starts)
Heating set point The temperature at which heating is activated
Evaporator The area where the refrigerant absorb the heat from the
internal enclosure
Condenser The area where the refrigerant give off heat to ambient air
Heat load The heat incl. solar gain that is to be removed from the
shelter or room

8
Product description
Overview
Introduction This section will give you a description of the Silencio and its functionality.
Content This section covers the following topics:
Topic See page
General description next page
Description of parts 11
Description of the control board 14
Functional description 17
Set points 20
Control strategy 21

9
018717 • Version 1.1 • 23.01.2007
General description
Introduction This section gives you a description of the unit as a whole. The following section
describes the different parts in details.
Description The Silencio is designed to control the internal environment of a universal shelter or
room.
The Silencio removes excess heat from sensitive electronic equipment and is especially
suited in applications where the equipment requires to be maintained within defined
temperature limits to achieve optimum performance and to maximize component
lifetime.
We have designed the Silencio to generate a minimum of externally generated sound
bearing strict regulations of sound emissions in mind.
Silencio is designed to be mounted outdoor.
Versions Silencio is available in the 4 sizes:
•Silencio 600, 6 kW
•Silencio 800, 8 kW
•Silencio 1000, 10 kW
•Silencio 1400, 14 kW
Drawing, internal This drawing illustrates the different parts, visible from the internal side:
Continued overleaf
d
k
d
e
f
g
h
ij

10
General description, continued
Illustration,
external This illustration gives an overview of the parts and systems, a more detailed description
will follow in the section “Description of parts”, on page 11:
Part Part
gExternal condenser fan
cTemperature sensors, see section
“How to replace the temperature
sensors”, page 56 hControl board
dFilters iCompressor
eDamper motor jHeater
fInternal fan k25 poled SUB-D connection
d
e
f
g
i
j
d
g

11
018717 • Version 1.1 • 23.01.2007
Description of parts
Introduction This section will give you a more detailed description of the parts of the Silencio.
The parts that will be described are:
•Temperature sensors
•Filters
•Damper
•Internal fan
•External condenser fan
•Compressor
•Heater
•Control board
•25 poled SUB-D connection
Temperature
sensors The purpose of the temperature sensors is to provide the control board with signals.
High or low temperatures (compared with set points in the control board) result in a
signal from the control board to either the air conditioning system or the heating system.
Sensor Placement Result
Return air sensor Placed in the return air duct Gives a representation of the
enclosure temperature
Supply sensor Placed in the supply air duct Gives a representation of the
supply air temperature
Ambient sensor Placed below the PPI filter at
the bottom of the unit, secured
to the net
Gives a representation of the
ambient temperature
Condenser sensor Placed in a sensor pocket on
the liquid pipe, at the cooling
system
Gives a representation of the
temperature of the refrigerant
Filters The purpose of the filters is to prevent dust from entering the shelter.
The main filter is a pleated DVI filter, class F5, (96 % degree of separation).
The PPI filter is for protection of external fans and condenser against insects and
leaves etc. See section “General description”, page 9 for replacement of the filters.
Damper The damper is used when the Silencio runs in a free cooling mode or emergency
cooling mode, and will move back and forth to maintain a steady temperature in the
shelter or room.
The purpose of the damper is that the Silencio can run in a free cooling mode.
See more about free cooling mode in section “Functional description”, page 17.
Continued overleaf

12
Description of parts, continued
Internal fan The internal fan draws return air from the shelter into the Silencio, to:
•Circulate the internal air, when the return temperature is not too high (Recycle)
•Draw out the return air and push it through the air condition system to cool the air
(active cooling)
•Blend the return air with fresh air and push this new cooled air back to the shelter
(recycle/free cooling)
•Push warm air from the shelter to the outside in order to remove excess heat (free
cooling)
•Circulate the internal air and push it through the heating system to warm up the
supply air back to the shelter (heat)
•The internal fan is active in all modes, and runs continuously in various speeds.
External
condenser fan The external fans draw ambient air into the Silencio to:
•Cool the condenser (active cooling), or
•Provide ambient air to the shelter (free cooling or emergency cooling)
•The external fans are active in active cooling, free cooling and emergency cooling
Compressor The compressor circulates the refrigerant in the cooling system.
Heater The heater keeps the internal temperature at an adequate level at low ambient
temperatures, and is often also used to heat up the shelter in start up conditions.
Control board The control board allows the user to change settings and to obtain information.
The control board controls the following active parts:
•Heater element
•Damper
•Internal fan
•Compressor
•Condenser fan
Learn more about the control board in section “Description of the control board”,
page 14.
25 poled SUB-D,
illustration This illustrates the SUB-D plug:
Continued overleaf
1
14 25
13 7
20

13
018717 • Version 1.1 • 23.01.2007
Description of parts, continued
25 poled SUB-D,
connections The 25 poled SUB-D connection gives you the possibility of connecting additional
external equipment (see table below).
Furthermore you have the same functionality as the RS485 communication port, for
details about this, see section “Description of the control board”, page 14.
Warning!
A male Sub-D 25 connector with a connection between 5 and 12 is mounted on the
female Sub-D 25 connector. A removal of this male Sub-D 25 connector during
operation will cause the unit to stop.
Sub-D 25 connections
The following explain the connections. The connector is shown from above:
Pin
no. Color Description Function Default setting
1 White/Blue Hotspot sensor Input -
2 Blue/White Hotspot sensor Input -
3 White/Orange Alarm Output Normally closed
4 Orange/White Alarm Output Normally closed
5 White/Green Smoke alarm Common -
6 Green/White Warning Output Normally closed
7 White/Brown Warning Output Normally closed
8 Brown/White Fault Output Normally closed
9 White/Gray Fault Output Normally closed
10 Gray/White Interconnection + Input -
11 Red/Blue Interconnection - Input -
12 Blue/Red Smoke alarm Input Normally closed
13 Red/Orange Occupied Input Normally open
14 Orange/Red Humidity sensor Input Normally open
15 Red/Green Not connected - -
16 Green/Red Analogue input 2 Input -
17 Red/Brown Analogue/Occupied/Humidity Common -
18 Brown/Red Not connected - -
19 Red/Gray RS485A Output -
20 Gray/Red RS485B Output -
21 Black/Blue Not connected - -
22 Blue/Black Not connected - -
23 Black/Orange Not connected - -
24 Orange/Black Not connected - -
25 Black/Green Not connected - -

14
Description of the control board
Introduction This section gives you a detailed description of the control board and its test function.
Description of how to change settings is to find in section “Users guide”, page 31.
DanCon All Silencios are provided with a DanCon control board.
Illustration This drawing illustrates the control board:
Part/function This table gives you a description of each part on the control board:
Part Function
cLED The LEDs show the status and the alarm
Learn more about the status and alarms in the
following
Test By pressing this button the unit will run
through a quick test program.
Any detected fail can be read on the fail LED
Occupied By pressing this bottom the unit will go into the
occupied function. Learn more about the
occupied/service function in section
“Functional description”, page 17
Dials These dials give you the possibility of
changing the heater and/or the cooling set
points, see more in the section “Set points”,
page 20 and in the “Users guide”, page 31
RS485 communication port These ports give you the possibility of
connecting a pc and/or DanLink
telemonitoring program (accessory)
Locking mechanisms The locking mechanisms must be released to
remove the control panel. Remember to lock
the locking mechanisms whenever a control
board has been released.
Continued overleaf
cdefh
g
h

15
018717 • Version 1.1 • 23.01.2007
Description of the control board, continued
Signals of LED The LED gives you different signals. The below table gives you a description of each
signal:
Part Function
1 × Green LED Supply Lit as soon as the controller is powered up
3 × Yellow LED Compressor Lit when the active cooling is operating
Heat Lit when the heater is operating
Link Lit when (and 10 min. after) valid
communication is in progress
1 × Red LED Fail Lit in case of a detected failure, see details in
section “Fault finding guide”, page 71.
Test description When activating the test button the unit starts the test program. The unit will run through
the different tests according to the below table.
The fail LED will operate normally indicating fail if and when detected.
If any fail is detected during the test, the LED will flash with a frequency of 1 Hz for
30 seconds after the test is done to indicate some fault were detected.
Test points,
Silencio 600 Here are the test points for the Silencio 600:
Test point
Description
Heater
Damper
Internal fan
Compressor
Condenser fan
LED
Duration
1IDLE Off Closing Stopped Stopped Stopped Jingle 30 sec.
2Heating
mode
On Closing 400 RPM Stopped Stopped Normal 60 sec.
3Free
cooling
Off Opening 700 RPM Stopped 450 RPM Normal 60 sec.
4Active
cool
Off Closing 700 RPM Running 700 RPM Normal 60 sec.
5IDLE Off Closing Stopped Stopped Stopped Normal 30 sec.
Continued overleaf

16
Description of the control board, continued
Test points,
Silencio 800, 1000
and 1400
Here are the test points for the Silencio 800, 1000 and 1400:
Test point
Description
Heater
Damper
Internal fan
Compressor
Condenser fan
LED
Duration
1IDLE Off Closing Stopped Stopped Stopped Jingle 30 sec.
2Heating
mode
On Closing 700 RPM Stopped Stopped Normal 90 sec.
3Free
cooling
Off Opening 1000 RPM Stopped 1050 RPM Normal 90 sec.
4Active
cool
Off Closing 1400 RPM Running 1400 RPM Normal 90 sec.
5IDLE Off Closing Stopped Stopped Stopped Normal 30 sec.

17
018717 • Version 1.1 • 23.01.2007
Functional description
Introduction Silencio operates with 2 systems and in 7 different modes.
The 2 systems, which are described in the following, are:
•Air conditioning system
•Heating system
The 6 modes, which are described in the following, are:
•Active cooling
•Free cooling
•Recycle
•Heat
•Emergency cooling
•Service
Air conditioning
system The purpose of the air conditioning system is to cool the supply air in order to lower the
temperature inside the shelter.
The air conditioning system is an on/off system.
The control board is controlling the compressor in accordance with the return
temperature.
Heating system There are two purposes of the heating system:
•Cold start-up conditions
•Cold ambient temperatures
The heating system will be operating when the temperature gets too low in the shelter.
The heat dissipation from the heater is 2000 W depending on the ambient
temperatures.
The heater turns of when the return air temperature reaches 15 °C
Active cooling In active cooling mode the
compressor, the internal fan and the
external fans are operating in order to
circulate refrigerated air into the
shelter, and to exhaust the heat drawn
from the internal air through the
condenser in the external circuit.
The Silencio will switch to active
cooling mode when the temperature in
the shelter reaches 27 °C*)
*)Set points can be adjusted, see
section Set points, page 20
Continued overleaf

18
Accessories, continued
Free cooling In free cooling mode the damper, the
internal fan and the external fans will
operate to provide exactly the fresh air
amount needed to keep a constant
temperature in the shelter/room
(3 degrees below the cooling set
point).
*Set points can be adjusted, see
section Set points, page 20
Recycle Recycle mode occurs when there is no
need for cooling or heating. The only
component active will be the internal
fan (necessary to prevent local hot
spots).
*Set points can be adjusted, see
section Set points, page 20
Heat In heating mode the heating element
and the internal fan will operate to keep
the shelter/room temperature above the
heating set point.
Continued overleaf

19
018717 • Version 1.1 • 23.01.2007
Accessories, continued
Emergency
cooling Emergency cooling will occur when
there is either compressor fault or loss
of AC power.
Since active cooling is not possible, the
damper will attempt to provide fresh air
cooling to keep the return temperature 3
degrees below set point even when it is
not possible because of high ambient
temperatures.
At compressor fault:
The compressor fault timer must have
returned to zero before the emergency
cooling situation will end.
At loss of AC mains:
Mains AC power must be back before
the emergency cooling situation will end.
Service/occupied
mode The service mode should be activated to
make a comfortable climate in the
shelter during service.
In service mode the unit will switch
between active cooling, free cooling,
heating and recycling to maintain:
•comfort temperature between
20-25 °C
•low fan speed to reduce sound level
and air flow
Service mode is only for use when
technicians are working in the shelter.
After one hour in service mode the unit
automatically switches back to normal
operation.
It is possible to reactivate the button for
another period of one hour.

20
Set points
Introduction This section gives you information about the set points.
The following topics will be described:
•Factory settings
•How to change set points
General This section describes how to change set points on a stand alone unit without any of
the accessories DanView or DanLink. Changing settings with DanView or DanLink
please refer to the manuals for these products.
Factory settings The factory settings are as follows:
Set point Factory Range
Heater 5 °C 0 °C to15 °C
Active cooling 27 °C 20 °C to 40 °C
How to change Using the dials on the front of the control board you are able to change the above
settings.
Limitations Limitations in set points: Please notice that the minimum difference between cooling
and heating set point must be 10 degrees or more to avoid
fighting between active cooling and heating.
For further information about the set point settings, please see section “Users guide”,
page 31.