Dantherm 3500 User manual

DC Split Air Conditioner 3500
EN Installation manual
Rev. 1.0

2
EN
Introduction
Introduction! This is the Installation manual for the Dantherm DC Split Air Conditioner 3500.
Please see the below table of content for further information about the sections.
Target group The target group for this service manual are the technicians who install and maintain the DC
Split Air conditioner 3500 unit, as well as the users of 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 reserves the right to make changes and improvements to the product and the
service manual at any time without prior notice or obligation.
Table of contents Topics Page
Introduction 2
Product description 4
Accessories 6
Installation 7
Safety Precautions 8
Leakage test, Evacuating and lling the system 16
Operation 18
Error list 20
Connections 21
Modifying the conguration le 22
Electrical schematic 26
Cooling circuit 30
Technical Data and dimensions 31
Spare parts 33

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Product description
Introduction! This section describes the overall product, and its functionality
Usage of the DC Split
Air conditioner 3500
The DC Split Air conditioner 3500 is designed to control the internal temperature of an
outdoor enclosure. The DC Split Air conditioner 3500 removes dissipated heat from electronic
equipment and it´s designed to maintain correct temperature for electronic equipment.
Cooling system The DC Split Air Conditioner 3500 is equipped with a hermetically sealed cooling system.
The outdoor unit is pre-lled with 1100gram refrigerant R134a.
The GWP (Global Warming Potential) is1430
Important Dantherm Air Handling recommends that the cooling system should be powered continuously!

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Indoor unit This illustrates visible parts of the indoor unit.
Parts description
indoor unit
The Indoor unit contains the evaporator coil, two evaporator fans and the main controller CC0.
The warm air is sucked in through the front, and blown out at the bottom of the unit, the air
direction can be adjusted to horizontal by the adjustable louver.
Product description, continued
Air inlet
Louvers
Change of air direction
Air outlet
Controller
• Adjust setting
• SD card TTL link
• RS 485 Modbus
• Alarm output
• A/C connect
• Dig input
• Hotspot

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Outdoor unit This illustrates the visible parts of the outdoor units
Parts description
outdoor unit
The outdoor unit contains the condenser coil, condenser fan, compressor, compressor drive
and 48VDC Power input for the entire unit.
Top Service Cover
Connection for
hose and power
cable.
Unit support
Bracket
Condenser
Air Outlet
Fan Air
Inlet
Product description, continued

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Description Art. No.
Wall bracket and two bars for outdoor unit. Including screws.
Dimension(HxLxW): 254 x 466 x 52mm
092957
Light model rubber feet for outdoor unit made of durable recycled rubber. Reduces
vibration from the unit and provides stability.
Aluminium channel securely anchored in top for easy xation of the unit.
Quick and simple installation.
Boxed kit with xings. Including two bars and screws.
Dimensions (HxLxW): 95x450x160 mm
Weight: 4,8kg
097025
Heavy model rubber feet for outdoor unit made of durable recycled rubber which
reduces vibration and provides stability.
Aluminium channel securely anchored in top for easy xation of the unit.
Quick and simple installation.
Boxed kit with xings. Including two bars and screws.
Dimensions (HxLxW): 95x1000x160 mm
Weight: 10,3 kg
097026
Shock and vibration absorber includes a set of four absorbers for outdoor units.
The absorbers can be mounted on wall bracket and ground mat. 074666
Adapter bars for mounting the outdoor unit on existing wall brackets. Including two
bars and xation. Length: 1000mm 097027
Condenser pump for drainage for indoor unit.
Voltage: 230V/50Hz Max 0,11 Amps
Max 6 litres per hour at lift height 7m
For indoor use only.
Kit includes:
•Pump, level sensor mounted at wall bracket
•5m Ø4/Ø8 tubes for drainage outlet
•Adapter for connecting to 1/2”drainage hose
•Anti siphoning device.
097028
3m copper tubes 3/8”& 1/2”with 10mm insulation and UV protection. Tubes are
prepared for easy connection with ares and are nuts. 097079
5m copper tubes 3/8”& 1/2”with 10mm insulation and UV protection. Tubes are
prepared for easy connection with ares and are nuts. 097029
10m copper tubes 3/8”& 5/8”with 10mm insulation and UV protection. Tubes are
prepared for easy connection with ares and are nuts. 097030
Dantherm RS485 display unit
075210
SD card 2GB for logging data. 087432
Accessories
52
0
42,5
235
254
466
543
kny
04-10-16
A
14-11-2017
kny
A
g
SCALE: NOT TO SCALE
092956
092956
MATERIAL:
THICKNESS:
WEIGHT:
REV. BY:
DATE:
REF.:
DATE:
PART NO REV.:
REV.:
PART NO
Sheetmetal flatstate is based on Dantherm Air Handling A/S
process equipment and is only intended as a guide.
Mounting bracket (set of 2) for Split AC
Ophængsarm (sæt af 2) for Split AC
8
This Drawing is furnished with the understanding that the
essence there of will not be reproduced in whole or in part
without written authorization by Dantherm Air Handling A/S.
All designs originated by Dantherm Air Handling A/S are the
property of said Company and will be protected by Patents.
Surface appearance according to reference
table LZT 142 0001, category
Linear dimensions without tolerances according to
DS/EN 22768-1 medium. Angular dimensions without tolerances: ± 1°
446
254
52
543

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Included in the package Description Number Please note
Indoor unit 1 -
Wall bracket, indoor unit 1 -
Outdoor unit 1 Incl. refrigerant R134a, 1100 gram.
Communication cable 10m Installed at outdoor unit. Fit with
connector for indoor unit.
Power supply cable, 2 x 4mm29m Installed at outdoor unit. Flying leads
at opposite end.
Alarm connector 9 pin for Controller 1
Flarenut for 3/8”copper tube indoor unit 1
Flarenut for 1/2”copper tube indoor unit 1
Flarenut for 3/8”copper tube outdoor unit 1
Flarenut for 1/2”copper tube outdoor unit 1
Drainage hose for indoor drain pan 3m 1/2”Reinforced plastic.
Clamp for drainage hose 1
Manual 1 Part number: 095106
Parts needed for installation There might be need for further installations parts whicha are not supplied with the Dantherm
DC Split Air Condition 3500.
• Any screws for mounting indoor and outdoor unit
• Ø85mm plastic sleeve for wall hole
• Sealant for wall hole
• Wall bracket for outdoor unit
Required tools
For installation
To perform a proper installation you need the following tools before starting the installation.
• Level gauge
• Electric Drill
• Suitable drill according to the wall type
• Hole core drill Ø85mm
• Screw driver for Torx
• 2 adjustable wrench
• Refrigerant gas leak detector
• Nitrogen for drying the cooling system
• Wacuum pump
Installation

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Before Installation To prevent the injury of user or other people and property damage, the following in-structions
must be followed
• Be sure to read before installing the DC Split Air Condition 3500
• Be sure to observe the cautions specied here as they include important safety related
issues
• Incorrect operation due to ignoring instruction will cause harm or damage
Installation • Always ground the unit
• Securely connect the electrical power
• Ensure that the cover connections of the outdoor unit are not damaged.
• Do not install the product in a high place with the risk of it falling down.
• Install the drain hose to ensure that condensed water can be drained.
• Always inspect for gas leakage after installation and repair of the product
Installation
requirements
Incorporate the following when installing the electrical connections:
1. DC external supply should be protected with an external circuit breaker at 35 Amps
2. Label disconnected devices, stating rated voltage and rated current.
3. It is imperative to secure and install all connections to prevent any damage to
equipment and/or humans.
Secure all cables with cable ties or appropriate cable fasteners.
Operation WARNING
• Make sure all power is disconnected prior to installation, maintenance or service.
• Do not allow water to run into electrical parts
• Do not place obstacles around the air ow inlet or outlet
Safety Precautions

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EN
Select the best location To ensure maximum eeciency mount the indoor unit near but not too close to the ceiling.
Secure the unit in a manner so there is ample room for maintenance and service after
installation.
Wall Bracket Level and mount the bracket for indoor unit.
Installation of indoor, outdoor unit
7mm holes
Wall bracket
If distance is 100mm it is
required that tubes and wires
are connected before installing.

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Installation of indoor, outdoor unit, continued
The outdoor unit can´t be installed further from the indoor unit than the enclosed cables and
copper tubes can be used without any extensions. The length is 3,5m.
This is easily obtained by installing the indoor unit near the ceiling and the outdoor unit on the
other side of the wall near the ground.
The outdoor unit needs some free space between the wall and air intake, see below
If the outdoor unit is to be installed close to the seaside, direct exposure to the sea should be
avoided. Install the outdoor unit at the opposite side of wind direction or install a windbreaker in
front of the Outdoor unit but not closer than 70cm.
The height of the windbreaker should be 150% of the height of the outdoor unit

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Preparing
Indoor unit
Unscrew the four screws and remove the right end cover of the indoor unit as shown below.
Prepare piping between
indoor and outdoor unit
The piping between the indoor and the outdoor unit is not included in the DC Spilt Ari
Conditioner 3500. It can be provided from Dantherm or it can be prepared by the installer.
Dantherm can provide prepared piping sets at 3, 5 or 10 meters.
See accessories list.
For installers providing the copper piping.
• For liquid line: use 3/8" pipe
• For suction line: use 1/2" pipe
Flare nuts are to be used with both indoor and outdoor units. The are nuts are included.
Measure and cut the required lengths of pipe. Put a are nut on the pipe and make a are on
the pipe. This is to be done at both ends of the pipe.
Pre-charged outdoor unit The outdoor unit comes pre-charged with 1100 grams of refrigerant R134a.
This is for piping lengths up tp 3 m.
For longer pipings additional 20 grams of refrigerant R134a per meter is needed.
Examples:
Pipe length Additional refrigerant R134a
5m 40 grams
10m 140 grams
Installation of indoor, outdoor unit, continued

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Connecting the piping Find the two insulated rubber hoses and connect the ares to the indoor Unit.
Align the Center of the pipe/hose and tighten the are nut by hand
And then tighten the are nut with a wrench
How to connect the
cooling pipes.
9-pin connector
12-pin connector
Grounding
Suction Line 1/2" Flare nut
Drainage
Liquid line 3/8" Flare nut
Flare nut Tightening
Torque [Nm]
3/8 liquid line 20 to 25
½”suction line 34 to 47
Secure the drainage hose with
the hose clamp.
Installation of indoor, outdoor unit, continued

13
EN
Wall hole for piping and drain Drill a Ø85 hole through the wall for piping, cabling and drain hose,
See sketch below
Secure the hole with a plastic sleeve in order to avoid sharp edges, this can also be done with
heavy duty tape
Mount indoor unit Place the indoor unit on the hooks of the wall bracket, and secure the unit with two screws at
the bottom of the unit and into the wall.
Prepare the outdoor unit The outdoor unit comes with pre-installed cables, one supply power cable with two wires:
red + and blue -. The cable length is 9 m. The power cable must be connected in a Circuit
breaker with max load of 35 Amps inside the shelter.
The other cable is also pre-installed to the outdoor unit. This cable contains 20 wires for
communication between indoor and outdoor unit and power to the indoor unit.
The cable length is 10 m and should not be extended.
The communication cable is tted with two AMP connectors:
one with 9 pins and one with 12 pins.
The AMP connectors t the indoor unit.
Find the right position for the outdoor unit and x it to the ground or wall bracket.
Outside
Inside
Installation of indoor, outdoor unit, continued

14
EN
Cables and ares Put the the two cables through the hole in the wall.
Next pull the cooling pipes and drainage from inside through the hole in the wall.
Do not bend or block the drain hose.
Be careful not to make a sharp bend at the refrigerant pipes.
Connect the ares from the hoses to the service valves.
Tighten the are nut carefully rst by hand and afterwards use the wrench to tighten up.
Installation of indoor, outdoor unit, continued
½" - 20 UNF

15
EN
Electrical installation Plug the communication cable into the plug on the right side of the indoor unit
The communication cable is a shielded cable and needs a secure grounding at the indoor unit,
use the metal cable tie at the indoor unit to make that grounding
Connect the Power cable + and – to the 48VDC circuit breaker
Ground the unit.
Do not power on yet.
9-pin connector
12-pin connector
Liquid line 3/8" Flare
Screw this on shielded cable
Grounding
Installation of indoor, outdoor unit, continued

16
EN
Leakage Test The Outdoor unit is lled with refrigerant R134a for the whole system. This unit is hermetically
sealed. The only access is through the two service valves located on the side of the unit.
The indoor unit and the piping is open and the connections need to be checked for leakage .
Check that each tube-both liquid and gas side tubes have been properly connected.
Remove the service valve caps from both liquid and gas side on the outdoor unit.
Check that both liquid and gas side service valves on the outdoor unit are kept closed at this
stage.
Connect a manifold valve with pressure gauges and dry nitrogen gas to the service port with
gas side (large valve.)
Be sure to use a manifold valve for leak testing. The high side manifolds must always be closed.
Pressurize the system with dry nitrogen gas to more than 10 bar.
Close the valve when the gauge reading reaches 10 bar.
Test the for are connection with liquid soap
Bubbles indicate a leak, and the connection needs to be redone until no leakage remains.
After the system is found to be free of leaks relieve the nitrogen pressure by loosening the
charge hose connector at the nitrogen gas cylinder.
Charge hose
Nitrogen gas
cylinder (in vertical
standing position)
L o Hi
Manifold valve
Pressure
gauge
Place the nitrogen gas
cylinder in a vertical position
during this tes.
Leakage test

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EN
Evacuation Connect the charge hose end to the vacuum pump to evacuate the tubing and indoor unit.
Conrm the Lo knob of the manifold valve is open.
Then, run the vacuum pump.
The vacuum pump must be operated at less than 0,8torr of the gauge pressure
When the desired vacuum is reached, close the Lo knob of the manifold valve and stop the
vacuum pump.
Charging and nish
1. Use a wrench to turn the valve stem of liquid side valve counter- clockwise to fully
open the valve
2. Turn the valve stem of gas side valve counter-clockwise to fully open the valve
3. Loosen the charge hose connected to the gas side service port slightly to release the
pressure, then remove the hose
4. Replace the are nut and its bonnet on the gas side service port and fasten the are
nut securely with an adjustable wrench.
This process is very important to prevent leakage from the system!
5. Replace the valve caps at both gas and liquid side service port and fasten them tightly
This completes air purging with the vacuum pump and ll the whole system with refrigerant.
The DC split Air condition 3500 is now ready for its´ rst test run.
L o Hi
Manifold valve
Pressure
gauge
Vacuum pump
Open
Close
Charge hose
Evacuation

18
EN
The adaptive cooling strategy guarantees the lowest power consumption at all time during
operation.
Reduces wear and tear of cooling system, and lowers acoustical noise level.
• SD card* socket for data logging and conguration.
• RS 485 RTU ModBus*. (Monitoring and remote user panel)
• Real time clock and calendar.
• 7 segment display* for temperature readout and setpoint adjust.
• Digital input and Alarm output*
Components The CC0 controller has two onboard LEDs.
Green LED indicates operation, red LED will indicate fail or lock mode
During SD card read/write process, green LED will icker.
A onboard 4 digit, 7 segment display, is available for temperature information and adjustment of
cooling and heating setpoint.
The CC0 has a RTU ModBus communication protocol.
Hardware layer, RS 485, RJ 45 connector.
Baud rate: 9600,n,8,1
Operation

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Step down EnterStep up
Menu structure and
navigation.
Step up/down to jump through menues, end.
Enter to select the parameter to read or change
Step Action Display
Hibernate mode shows the actual room tempereature.
After 3 minutes without activity on the keys, the controller exits any menu and
shows this. Use up/down to select menu point below
Cooling setpoint
parameter
Press enter for 2 seconds to change value. Enter
to save.
Heater setpoint
parameter
Press enter for 2 seconds to change value. Enter
to save. Note: Heater is not installed in this
product
Operation error list.
See list below.
Press enter for 2 seconds to change reading to
see if more errors are present simultaneously.
Override test.
This will run a
series of tests.
See list on
next page.
Press enter for 2 seconds to start test cycle. The
test steps will increase automatically by one
after 60 seconds or changed manually using up/
down.
If it is left idle, the test will auto disable after 30
minutes.
Alarm mode Via onboard navigation keys and display, alarm mode can be initiated. Can be used for service
purpose, and fault nding.
Press up/down key, until “err” is visible in display. Now press enter.
By use of up/down key, it is now possible to toggle between error codes.
Error codes shown in display, are masked error codes, related to which errors/alarms that are
mapped to the alarm relay output.
See section about controller conguration.
Operation, continued

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Error list
If any failure happens at the cooling mode an error code will show in the display. The error - Exx and the
corresponding corrective action can be found in the table below.
Display error No. Error description What to do
E01
The supply voltage is higher than the pre-set
60VDC, and the Controller stop the unit.
Check the rectier and adjust the supply
voltage to below VDC and the unit start up
automatically.
E02
The supply voltage is lower than the pre-set
40VDC, and the Controller stop the unit.
Check the batteries and rectier and rose the
supply voltage to over VDC and the unit start
up automatically.
E03
The actual Amps are higher than the pre-set
30A and the Controller stops the unit.
The cooling unit is out of normally operation
conditions, the unit will starts up again
automatically when compressor restart time
out has expired. (90 sec)
E04
The actual amps are lower than the pre-set 1A. The cooling unit is out of normal operation
conditions. An alarm can be given if
congured.
E05
The room temperature is higher than the
preset 40°C or lower than the preset 0°C.
The unit will continue running.
This is a temperature warning that tells the
room temperature is far away from the cooling
setpoint.
E06 Internal Fans have failure and have stopped or
they are not working properly.
Check the internal fans, and replace them if
necessary.
E07 The Condenser Fan has failure and has
stopped or it is not working properly.
Check the Condenser fan, and replace if
necessary.
E08 The compressor motor has failure and is
stopped or not working properly.
Check the electric circuit, check the
compressor connections.
E09
The room temperature sensor mounted at
the indoor unit has fail and are not working
properly.
At the indoor unit, check the room
temperature sensor, either shortcut or a
missing connection.
E13
The temperature sensor mounted at the
condenser coil has failed and is not working
properly.
At the outdoor unit, check the temperature
sensor at the Condenser coil, either shortcut or
a missing connection.
E14 Digital input 1 active. Depending of what the Customer have
connected to digital input 1.
E15 Digital input 2 active. Depending of what the Customer have
connected to digital input 2.
E16
The cooling system have high pressure more
than 28barg the unit short down in order to
protect the unit. If more than 6 times,HP failure
within 1 hour, compressor will be locked.
Needs restart of unit.
Lack of air ow due to clogged condenser/oil
or airways at outdoor unit. Check the airways
and the condenser Coil, and clean them. The
cooling unit start up automatically when
pressure is equalized.
E17
The electronic located at the top of the
outdoor unit is hot, and the Cooling unit close
down to protect the unit.
Lack of air ow due to clogged condenser/coil
or airways at outdoor unit. Check the airways
and the condenser Coil, and clean them. The
unit will start up again automatically when the
electronics is cooled down.
E18
The compressor is too warm and the thermal
cut o stop the compressor.
This happens only in extreme conditions
where the outdoor temperature is above 55°C.
The unit will start up again automatically when
the compressor is cooled down and restart
time out has expired.
E19
The low pressure switch stops the cooling unit
in order to protect the compressor.
Can happen in low outdoor temperature
below -15°C and or lack of refrigerant in the
cooling system, rechargeR134a to the cooling
system, The cooling unit start up automatically
when pressure is equalized.