Dantherm 6000 Service manual
Below you will find brief information for Air Conditioner DC 4000, Air Conditioner DC 6000. The air conditioners are designed to control the internal temperature of an outdoor enclosure. The air conditioners remove dissipated heat from electronic equipment and are designed to maintain correct temperature for electronic equipment.
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DC Air Conditioner 4000/6000
Service manual
Rev. 2.0
en
Der tages forbehold for trykfejl og ændringer
Dantherm no se Responsabiliza por Cambio y Posibles Errores
Dantherm can accept no responsibility for possible errors and changes
Irrtümer und Änderungen vorbehalten
Dantherm n’assume aucune responsabilité pour erreurs et modifications éventuelles
Introduction
Overview
Introduction
Target group
Copyright
Reservations
Table of contents
This is the service manual for the Dantherm DC Air Conditioner 4000/6000 series.
Please see the below table of content for further information about the sections.
This service manual is designed for technicians who install and maintain the DC Air
Conditioner, as well as the users of the unit
Copying of this service manual, or part of it, is forbidden without prior written permission from Dantherm Air Handling A/S.
Dantherm reserves the right to make changes and improvements to the product and the service manual at any time without prior notice or obligation.
This service manual covers the following main topics:
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
3
4
Warning
Introduction
This installation manual and the product use various displays and labels to ensure safe use.
Failure to follow these instructions could result in injury, death or damage to equipment.
Ignoring these displays and labels and incorrectly using the product could have results as classified below.
Please read the following warning symbol information before reading the rest of this section, and be sure to strictly observe all instructions.
General precaution
This product is not intended for use by persons (including children) with reduced physical, sensory or mental capabilities, or lack of experience and knowledge, unless they have been given supervision or instruction concerning use of the product by a person responsible for their safety.
Children should be supervised to ensure that they do not play with the product.
If the supply cord is damaged, it must be replaced by the manufacturer, its service agent or similarly qualified person in order to avoid a hazard.
Failure to follow these instructions could result in death or serious injury
Failure to follow these instructions could result in injury or property damage.
This symbol means something that should NOT be done
Project safety is your responsibility!
Follow the instructions in this manual regarding the installation method and installation orientation. All work should be performed by qualified personal using safe work practices.
All proper personal protective equipment should be used. PPE required for this installation includes, but is not limited to:
• Safety glasses
• Hard hat
• Safety shoes
• Hearing protection
• Cut resistant gloves
• Face shield
• Proper work attire (long sleeve shirt and long pants)
Please strictly observe the following: Special Skill is required to install the Dantherm products.
Non-qualified personnel should not attempt any of the actions shown in this installation guide. Dantherm shall not be responsible for improper installation or any accidents, damage, or injury resulting from improper installation.
Product description
Overall description
Introduction
This section describes the overall product and its functionality
The Air Conditioner is designed to control the internal temperature of an outdoor enclosure.
The Air Conditioner removes dissipated heat from electronic equipment and is designed to maintain correct temperature for electronic equipment.
Model overview
Available accessories
This manual covers a series of air conditioners. Models available are:
Enclosure size inch
Cooling capacity/ btu
Heater power /watt
Voltage
External over current protection / A
H*W*D
29 -17.3-
11.3
4000
6000
500
500
48VDC
(40-60 VDC)
48VDC
(40-60 VDC)
15A DC
20A DC
Minimum supply cord dimension
AWG-10
AWG-10
This table shows the accessories available from supplier
No
707585
Description
Air Filter, A/C 4000
5
6
Overall description, continued
Outdoor view
This illustrates the unit’s outdoor view:
1
2
Outdoor part description
Drainage
3
Fig. 1
The table shows the part description for the outdoor parts shown in Fig. 1:
2
3
Part
1
Description
Condenser air outlet
Removable front cover
Condenser Air inlet
This air conditioner includes a condensate drain in the bottom of the unit which routes condensed water away from the unit..
Fig. 2
Overall description, continued
Introduction
This illustrates the unit’s indoor view:
1
2
3
Indoor part description
4
Fig. 3
The table shows the part description for the indoor parts shown in Fig. 3:
2
3
Part
1
4
Description
Internal cooling controller
Evaporator fan
Removable front cover
Evaporator outlet
7
Overall description, continued
Functionallity
The illustration and table below show the airflow of the Air conditioner. The two air flows
(internal/external) operate separately. External air is only used to cool down the condenser which dissipates the heat absorbed by the indoor evaporator. The air flows are not mixed.
External Internal
8
Internal air flow
External air flow
Filters
Fig. 4
Warm, internal air is drawn into the unit by the internal evaporator fan, through the evaporator, and then released into the enclosure, through the evaporator opening.
Cold, external air is drawn into the unit by the condenser fan, and routed through the condenser, where it is cooling down the condenser. The air is returned to the external environment after it passes through the condenser.
The external air inlet in the bottom of the unit, has an optional pre-filter. This will reduce the instrusion of leaves or bugs in the air inlet.
The slide track in the bottom of the unit allows the user to slide in the pre-filter.
Accessory Embedded
Fig. 5
Electronic control description
This section describes key features of the electronic control and how it operates.
Introduction
Warning
Never perform installation, maintenance or service, without disconnecting the AC power supply.
Embedded
Controller
Basic parameters of the built- in controller can be set via the on board control panel from
inside the unit. See more in operation section page 12.
Extended parameter settings, as well as logging of operation data, is possible through the SD card interface.
Control strategy
Operation panel
The controller controls the fans, heater, and cooling compressor according to the temperature in return air flow.
• At power up, the controller will initiate a self test procedure for a few seconds.
• During operation, the evaporator fan will repeatedly circulate the indoor air.
• The compressor will start when the temperature is higher than the setpoint, which then initiates cooling.
• Then compressor stops at setpoint.
• The high temperature alarm will initiate an alarm on the alarm output when the temp is higher than 60° C.
• The low temperature alarm will initiate an alarm on the alarm output when the temp is lower than 1° C.
• The condenser fan operates only when the actual temperature on the condenser surface requires this.
Alarm connection options can be found on page 11.
This illustrates the operation panel, seen from inside of the unit.
Keypad Display In/outputs
Fig. 6
RS 485 TTL (PC)
9
Connections
Connections illustration
This illustration shows the external connections to the controller
10
Fig. 7
Connections, continued
The air conditioner can operate as a stand alone cooling system. For enhanced usage, it is possible to connect an external display with keypad.
See below table for options
Connection Specification
Alarm 1
Usage
This output will toogle state open/close if any operation errors occur.
Default open OR default close can be set via a jumper on the PCB.
Factory setting is normally open
Potential free
Max. 42 VAC or 60 VDC. /
500mA
Galvanic isolated (500V)
AC 1
Digital input 1
Digital input 2
This output will toogle state open/close if highest temperature limit setpoint is exceeded.
Default open OR default close can be set via a jumper on the PCB.
Factory setting is normally open
This input can control and overrule some operation parameters. See more in the parameters list
Active when low (0V)
This input can control and overrule some operation parameters. See more in the parameters list
Active when low (0V)
Potential free
Max. 42 VAC or 60 VDC. /
500mA
Galvanic isolated (500V)
0/12V DC
Internal pull up
Max. 10mA
0/12V DC
Internal pull up
Max. 10mA
NTC -30 to 85°C
(-22 to 185°F)
11
12
Operation
Introduction
Key operation
The unit can operate on the built in operation panel. All operation parameters are set via TTL or SD card. Cooling and heating setpoints are available in the control panel.
The functionality on the control panel is as follows:
• Left key is step up
• Middle key is step down
• Right key is enter
Up Down
Fig. 8
Enter
Operation, continued
Navigating menu
Menu structure and navigation. Step up/down to jump through menues, end enter to select the parameter to read or change.
Step Actions
Hibernate mode shows the actual room temperature. After 3 minutes without any activity on the keys, the controllers exits any any menu and shows this.
Use up/down to select any below menu
CooL
Cooling set-point parameter
Press enter 2 sec. and change the value followed by enter to save.
Heat
Heater set-point parameter
Err
Operation error list. See complete list
at section “Error list” on page 14
Test
Over ride test. This will run a series of component tests. See complete list
at section “Steps in test program” on page 14
Press enter 2 sec. and change the value followed by enter to save.
Press enter 2 sec. and change the readings to see if more error are present simultaneously.
Press enter 2 sec. to start the test. The test steps will increase by one after 60 seconds or be changed manually with up/down. The test will auto disable after 30 minutes, if not manually left before, with enter key
Display
24
C25
H05
E05
Toggle Celsius to
Fahrenheit readings
In hibernate mode press and hold the Enter key for 5 seconds to toggle Celsius and
Fahrenheit unit in all temperature readings.
13
14
Operation, continued
Error list
12
13
14
15
8
9
10
11
16
17
18
19
6
7
4
5
The below table shows the meaning of each error.
Code Error cause
1 High Volt [PHV][0/1]: 1
2
3
Low Volt [PLV][0/1]: 0
High Curr. [PIH][0/1]: 1
Low Curr. [PIL][0/1]: 0
Room Temp H/L [THL][0/1]: 1
Fan 1 [F1][0/1]: 0
Fan 2 [F2][0/1]: 1
DC Comp. [DCK][0/1]: 0
Ret Air Sens [RAS][0/1]: 1
Hotspot Sens [HSS][0/1]: 0
Evap in Sens [EIS][0/1]: 1
Evap out Sens [EOS][0/1]: 0
Cond. Sens [CDS][0/1]: 1
Digi.1 I/P [D1][0/1]: 0
Digi.2 I/P [D2][0/1]: 1
HP Pressure [HPE][0/1]: 0
DCC HeatSink [DHS][0/1]: 1
DCC Dig. 1 [DD1][0/1]: 0
DCC Dig. 2 [DD2][0/1]: 1
Steps in test program
5
6
3
4
The below table shows the steps in the self test program.
Step Test
0 NONE
1
2
AC_COMPR
AC_1
AC_FAN_1
AC_FAN_2
HEATER
EC_FAN_1
7
8
EC_FAN_2
DC_COMPR
9 ALARM
10 EEXP_VALVE
Installation
Introduction
Installation placement
Air Con wall cut out
This unit is designed to be mounted outdoor, flush to the wall. No other installation method isn’t recommended.
Never perform installation, maintenance or service, without disconnecting the AC power supply.
Any installation should allow good air flow inside the enclosure. The unit has cold temperature supply in the lower part and return air in the upper part of the unit as shown
on page 8. Please consider how to achieve the best possible air flow when selecting
appropriate placement.
A gaskit is included with the air conditioner unit. Additionally, we recommend the installation of polymer sealing on the exterior to prevent water instrusion
Please mark the cutout area and holes, according the below dimensions:
Fig. 9
Cut the two openings and drill the 9 pcs. with appropriate tools ( 8mm / 0,315”) to ensurr that no dust and debrees will accumulate into the enclosure.
15
16
Installation, continued
Preparation
Unpack the unit and place onto a table or similar stable placement.
The unit has small sheet metal parts that must be hand bent 90° in order for it to support the unit when attaching and securing the bolts and intalling the unit permanently to the wall.
The gasket (if not already installed onto the unit) can be found in the unit packaging. This should be installed according to illustrations below.
90° bend
Sealing strip
Installation
Fig. 10
Lift the unit into the cutouts and place it on the two brackets. Place the bolt from the inside, and secure them one by one, taking great care that no damage is done to the unit or enclosure due to small variation in enclosure structure.
After fastening all the bolts, the unit should be sealed on the outside, top and side junctions towards the enclosure.
Fig. 11
Installation, continued
Electrical requirements
Please incorporate the following imperative requirements when installing the electrical connections:
• Installation should always be in accordance with national wiring regulations.
• AC external supply should be protected with an external disconnecting device that has a contact separation of at least 3 mm. This external AC supply must also be over current protected. The disconnecting device must always be labeled with rated voltage as well as rated current.
• The unit’s earth connections must always be connected to the enclosures ground.
• All cables in a permanent installation, must be installed and secured properly to prevent any damage to equipment and/or humans. Secure all cables with cable ties or appropriate cable fasteners made for this purpose.
Electrical connections
After unit installation, the electrical connections should be completed, following below requirements:
1. The power and/or additional connections should be routed, secured, and connected to appropriate sources. The Air Conditioner is either delivered with:
A. 5 ft. cable with
Black lead: +48V
Red Lead: -48V
B. 6 ft. cable with
Black lead: +48V
Blue Lead: -48V.
2. If the power supply cord needs to be extended, always use at minimum, the same AWG.
3. All power supply connections should be secured with an external disconnection device.
Also ensure the connections are over current protected. The fuse specification for the
referring unit type/size can be found in the model overview table on page 5.
4. Connect any accessory needed according the specification to be found in the chapter for
external connections on page 11, Fig. 7.
17
18
Service Guide
Preventative maintenance
Introduction
Preventive maintenance has to be performed in order to:
• Continue operation in specified range
• Avoid malfunctions
• Avoid inefficient operation
• Maximize the unit’s lifetime
The factory warranty is only valid if documented preventive maintenance has been performed within time interval of:
• Maximum 6 months when unit is located in normal air quality environment
• Maximum 2 months when unit is located in bad quality air environment
A written log at site is adequate documentation for preventive maintenance.
Cleaning
CAUTION
• Switch off power supply before working on the unit.
• Make sure that all work has been performed correctly before switching power back on.
The unit must be cleaned according to the recommended preventive maintenance plan.
Tools required:
• Vacuum cleaner or compressed air
• Soft brush
• TX20 screwdriver
• AC cleaning agent if it is very dirty
4
5
Phase Description
1
Check and clean the outside air inlet grill. See page 8
2
3
Open the unit’s outer cover by removing the two screws in the lower edge of the cover
Vacuum the condenser coil and the visible part of the fan
6
Vacuum the evaporator coil from the inside of the enclosure.
IF any of the coils are still dirty, please apply AC cleaning agent on coil fins, and after 5 minutes, rinse gently with water WITHOUT spraying water on any electrical parts.
Perform end inspection according to the list in next section.
Preventative maintenance, continued
Inspection
The unit must be inspected prior to any re-assembly and put back into service. Please follow below steps:
6
7
8
9
3
4
Phase Description
1 Are the fans clean and free of any corrosion?
2 Are the coolant pipes free of obstructions, damage, corrosion and show no obvious signs of leakage?
Are the coil lamellars clean and undamaged?
Are all fan blades free of any obstructions, cracks or missing blades?
5 When rotating the fans with the fingers, do the fans rotate freely without vibrations and noise?
Is all wiring and insulation undamaged?
Are all connectors secured properly and in good condition?
Inspect the drain hose (if any) for damages.
Are any alarms visible on the controller? See page 9
Test cooling circuit
The cooling circuit is designed for long durability, and is comprised of a few components.
Any test of the circuit should be conducted only if a relevant problem has arisen .
Open the unit outside cover by removing the two screws in the lower part.
Locate the service valve and connect a pressure gauge. Confirm that the pressure is aligned with the present temperature according the read pressure.
Please be aware that with very low amount of refrigerant, its critical to use short hoses to the pressure gauge meter.
Test safety shut down
The compressor’s safety switch (Klixon) can be tested manually. Make sure that the unit’s cooling circuit is working before initiating this test.
Cover the condenser air inlet in the bottom of the outer cabinet with a piece of plastic or something similar. Bring the unit into continuous operation (lower setpoint inside the shelter), and expect shut down within a maximum one hour. If not, the switch is not working.
19
20
Spare parts
Illustration, external parts
Below illustration shows the available spare parts for the condenser section of the unit.
1
2
3
Sparepart list
External
Fig. 12
This list shows available spare parts for the condenser section of the unit.
2
3
3
Pos .
Number Description
1 081943 Coil, Compressor, DC4000 & DC6000
707746
216796
707752
Fan, 48VDC, DC4000 & DC6000
Compressor, DC4000
Compressor, DC6000
707769 Compressor Electrical Harness, DC4000 & DC6000
707594 Screw, M6 x 25, HEX Head, SS, DC4000 & DC6000
298043 Washer, 1/4", Flat, SS, DC4000 & DC6000
298044 Washer, 1/4", Spring Lock, SS, DC4000 & DC6000
707617 Gasket Kit, DC4000/6000 Mounting, DC4000 & DC6000
430651 Danaseal, DC4000 & DC6000
705842 NAMEPLATE MATERIAL, rev.b, DC4000 & DC6000
Spare parts, continued
Illustration, internal parts
Illustration to be added at a later date.
1
2
3
Sparepart list
Internal
4
5
Fig. 13
This list shows available spare parts for the evaporator section of the unit.
4
5
2
3
Pos .
1
Number Description
087280 CC0 Assembly with Housing and Overlay, DC4000 & DC6000
707746 Fan, 48VDC, DC4000 & DC6000
087281 Compressor DC Drive Control Board, DC4000 & DC6000
081942 Coil, Evaporator, DC4000 & DC6000
707739 Heater Element, 500W, DC4000 & DC6000
298681 Thermostat, temp limiting, manual reset, open 170F, DC4000 &
DC6000
707605 Thermostat, Automatic Reset, 140F, DC4000 & DC6000
086941 Inrush Filter Control Board, DC4000 & DC6000
218010 Capacitor, Compressor, DC6000
707778 Relay, Heater, DC4000 & DC6000
707634 Plug, Terminal Block, CC0 External Connections, DC4000 & DC6000
21
22
Technical data
Introduction
These units are designed for high reliability and electrical efficiency.
• Compressor is a rotary type with high efficiency.
• Radial fans with backward curved impellers.
• Slim MPE Condenser for high performance thus low pressure drop.
4000 btu . units
This table shows the technical data for 4000 & 6000 BTU models.
Specification Unit
DC Air
Conditioner
4000Z
Outdoor
Mounting Method
Unit dimensions
(height×width×depth)
Inch [mm]
DC Air-
Conditioner
6000Z
29.0x17.3x11.3 [737x439x286]
Weight
Performance 48VDC (40-60 VDC)
Cooling capacity at 131°F internal/
131°F ambient (55°C/55°C)
Cooling capacity at 95°F internal/
95°F ambient (35°C/35°C) lbs [kg]
BTU/h [W]
BTU/h [W]
4200 [1230]
3900[1140]
90 [40]
5900 [1730)
5300 [1550]
Internal airflow by air conditioning
External airflow by air conditioning
Refrigerant type
Operational temperature range
Noise, 1.5m distance
Heater
Electrical Data
Input voltage
CFM [m³/h]
CFM [m³/h]
°F [°C] dB(A)
Watts
Volts
250[425]
250[425]
<62
500
-40-+131 [-40 to 55]
48 (54) VDC
R134a
300[509]
300[509]
<65
700
48 (54) VDC
Max power consumption (Cooling)
Approvals
RoHS, ETL and cETL listed
Construction
Amps 12
Pending
16
Material
Galvanized Steel,
Stainless Steel Optional
Finish
Textured Powder Coat Standard,
Color options available by request
*Recommended over current protection specification to be found on page 5
Electrical schematics
Overall controller
This illustration shows the complete controller connections, internal as well as external:
Fig. 14
23
24
Electrical schematics, continued
Unit schematics
This illustration shows the unit’s schematics.:
Fig. 15
Any power supply shall be over current protected according table on page 5
25
26
Electrical schematics, continued
Unit schematics
illustration to be updated at a later date:
Cooling schematic
Introduction
This illustration shows the cooling circuit schematic.
Compressor Condenser
Evaporator
Line drier
Capillary tube
Fig. 16
27
28
Declaration of conformity
Declaration of
Conformity
Dantherm Air Handling A/S, Marienlystvej 65, DK-7800 Skive hereby declare that the Air
Conditioners are in conformity with the following directives:
UL 60335-1 . . . . . . . . . . . . . . . . . . . . . . Fifth Edition
UL 60335-2-40 . . . . . . . . . . . . . . . . . . . First Edition
CAN/CSA-C22.2 No. 60335-1-11 . . First Edition
CAN/CSA-C22.2 No. 60335-2-40 . . First Edition
Skive, 10.06.2014
Recycling
The unit should be recycled according to national rules and procedures to protect the environment. Please consult your local authorities for further information.
Index
A
AC 1 . . . . . . . . . . . . . . . . . . . . . . . . . 11
airflow . . . . . . . . . . . . . . . . . . . . . . . . . 8
alarm . . . . . . . . . . . . . . . . . . . . . . . . . . 9
B
bottom . . . . . . . . . . . . . . . . . . . . . . . . 6
C
celsius to fahrenheit . . . . . . . . . . 13
cleaning . . . . . . . . . . . . . . . . . . . . . 18
condensate . . . . . . . . . . . . . . . . . . . . 6
connections . . . . . . . . . . . . . . . . . 10
control . . . . . . . . . . . . . . . . . . . . . . . . 9
controller . . . . . . . . . . . . . . . . . . . . . . 7
cooling schematic . . . . . . . . . . . 27
cooling set-point . . . . . . . . . . . . . 13
crankcase heater . . . . . . . . . . . . . . . 5
D
declaration of conformity . . . . 28
digital input . . . . . . . . . . . . . . . . . 11
drainage . . . . . . . . . . . . . . . . . . . . . . . 6
E
electrical connections . . . . . . . . 17 electrical requirements . . . . . . . 17
electrical schematics . . . . . . . . . 23
error . . . . . . . . . . . . . . . . . . . . . . . . . 13
error list . . . . . . . . . . . . . . . . . . . . . 14
F
filter . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
H
heater set-point . . . . . . . . . . . . . . 13
hotspot sensor . . . . . . . . . . . . . . . 11
I
inspection . . . . . . . . . . . . . . . . . . . 19
installation. . . . . . . . . . . . . . . . . . . 15
M
maintenance . . . . . . . . . . . . . . . . 18
model overview . . . . . . . . . . . . . . . 5
O
operation . . . . . . . . . . . . . . . . . . . . 12
operation panel . . . . . . . . . . . . . . . . 9
over ride . . . . . . . . . . . . . . . . . . . . . 13
P
preventative maintenance . . . 18
R
recycling. . . . . . . . . . . . . . . . . . . . . 28
S
schematic . . . . . . . . . . . . . . . . . . . 23
sealing . . . . . . . . . . . . . . . . . . . . . . 16
selftest . . . . . . . . . . . . . . . . . . . . . . 12
selftest program . . . . . . . . . . . . . 14
spareparts . . . . . . . . . . . . . . . . . . . 20
T
technical data . . . . . . . . . . . . . . . . 22
W
wall cut out . . . . . . . . . . . . . . . . . . 15
29
Dantherm, Inc.
110 Corporate Drive, Suite K
Spartanburg, SC 29303 USA www.dantherm.com
+1 864 595 9800

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Key features
- Control internal temperature
- Remove heat from electronic equipment
- Maintain correct temperature
- Includes a condensate drain
- Optional pre-filter
- Embedded controller with control panel
- Extend parameter settings via SD card
- High and low temperature alarms
- Self-test procedure
- Modular design for easy maintenance