Dantherm Combo Cooling 6000/900 User manual

Combo Cooling 6000/900
Service manual
Rev. 1.0
en

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 modications éventuelles
Dantherm no asume ninguna responsabilidad sobre posibles errores o modicaciones

Introduction
Overview
This is the service manual for the Dantherm Combo Cooling series.
Please see the below table of content for further information about the sections.
Part number of this service manual is 367506 and covers units with serial numbers from
1404112107452
The target group for this service manual are the technicians who install and maintain the
Combo Cooling , 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 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:
Introduction .....................................................................3
Overview .............................................................................3
Warning ..............................................................................4
Product description ..............................................................5
Overall description ....................................................................5
Electronic control strategy. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
User guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Electrical connections ................................................................17
Alarm out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Digital inputs ........................................................................20
Operation errors .....................................................................21
Service Guide .................................................................. 22
Preventative maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Cleaning .............................................................................23
Inspection ...........................................................................24
Schematics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Spareparts ...........................................................................26
Technical data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Declaration of Conformity ............................................................30
Introduction
Manual
Target group
Copyright
Reservations
Table of contents
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Warning
This installation manual and the product use various displays and labels to ensure safe use.
Ignoring these displays and labels and incorrectly using the product could have results as
classied below. Please read the following warning symbol information before reading the
rest of this section, and be sure to strictly observe all instructions.
Not following these instructions could result in death or serious injury
Not following 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. Not following these instructions could result in injury, death, or damage to equip-
ment. All work should be performed by qualied 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-qualied 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.
Introduction
Warning
Caution
Warning
Caution
4

Product description
Overall description
This section describes the overall product, and its functionality
The Combo Cooling series is designed to control the internal temperature of an outdoor
enclosure. Combo Cooling series removes dissipated heat from electronic equipment and it´s
designed to maintain correct temperature for electronic equipment.
Dantherm recommends that the cooling system should be running continuously!
This table shows the accessories available from supplier
Description Illustration Order no.
ModBus external
display
075210
Filter G4 219304
Introduction
Important
Available
accessories
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Overall description, continued
This illustrates the units outdoor view:
1
2
5
4
3
Fig. 1
This table refers to the outdoor view above
Pos. Description
1 Free cooling air inlet
2 Condenser cooling air output
3 Front door with lock
4 Removable side cover for service access.
5 Condenser air inlet.
Outdoor view
Description
Outdoor parts
6

Overall description, continued
This illustrates the units indoor view:
1
2
4
3
5
6
Fig. 2
This table refers to the outdoor view above
Pos. Description
1 Free cooling supply air inlet
2 Return air
3 Cable routing, option 1
4 Cable routing, option 2
5 Removable installation bracket
6 Condenser fan
Indoor view
Description
Indoor parts
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Overall description, continued
This illustrates the units key components:
2
3
4
5
6
8
7
1
Fig. 3
This table refers to the parts view above
Pos. Descriptions
1 Free cooling fan
2 Wall bracket frame
3 Embedded controller, type CC4
4 Free cooling lter
5 AC/free cooling operation shift damper
6 Cable routing path
7 AC condenser
8 Removable condenser grill
Exploded view
Description
exploded parts
8

Overall description, continued
The illustration and table below show the airows of Combo Cooling.
The unit is combining free cooling and active cooling, to obtain the target temperature inside
the shelter application with lowest possible energy consumption.
The dierent cooling modes are:
1.Free cooling mode – Fresh outdoor air is used to cool
2.Active cooling mode – Air conditioner is used in a closed loop.
3.Circulation mode – Internal air is recycled (closed loop) without cooling
Air paths:
Free cooling Active cooling Circulation
Fig. 4
Warm, internal air is drawn into the unit by the internal evaporator fan, at the evaporator
opening, through the evaporator and the evaporator fan, and then released into the enclo-
sure through the evaporator fan opening.
Cold, external air is drawn into the unit by the condenser fan, and routed through the con-
denser, where it is cooling down the condenser. After passing through the condenser the air
is returned to the external environment through the two condenser fans.
Cooling
functionality
Internal airflow
External airflow
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Electronic control strategy
This section describes the key functionallity of the embedded CC4 controller.
For a complete description, Dantherm issues upon request, an extended manual for the
controller.
Never carry out any installation, maintenance or service, without disconnecting the power
supply (please notice that this units has dual power source AC & DC), by means of the exter-
nal power supply disconnecting devices.
The embedded controller, type: CC4, is designed to control the internal temperature of an
outdoor enclosure used for telecom equipment. Cooling units with embedded CC4 control-
lers, removes dissipated heat from electronic equipment and it´s designed to maintain cor-
rect and steady temperature for the electronic radio equipment.
The ComboCooler has both free cooling as well as AC cooling, thus still having connection for
additional external AC units.
The controller oers a wide range of external connections. See more at page 17
This below shown the overall cooling control strategy:
Function/
Fan RPM.
RPMbst
RPMhgh
RPMehgh
on
RPMlow
O
Thof
Thon
Tfof
Tset
Tibnd Tebnd
Dampers closed
Free cooling
Free cooling
high speed AC mode Boosted
Dampers closed
Dampers open
Dampers
open
Tfhg
Internal
compressor
Heater
External
AC
All AC on
Tco
Tcon
Teo
Teon
Tao
Taon
Temg
Indoor
temp
Fig. 5
If the outside temperature isn’t 3°C (default) lower than setpoint, the freecooling option will
be overruled, and the AC will take over.
Introduction
WARNING
Warning
Caution
Overall
Control strategy
10

User guide
The ComboCooler is designed with several option for operating the unit.
Interface Usage
RS485 ModBus Connect the universal and compatible Dantherm display unit, and gain
access to the main function immediately.
SD card interface
Insert an empty SD card and the controller downloads a conguration
and a logging le, OR insert an SD card with a cong le, and this cong
le will be automatically uploaded and initiated on the y.
Dantherm STRONGLY recommends to use the Dantherm RS485 external display. This has a
intuitive and easy to use basic operation controls which includes:
• Change master cooling mode.
• Change setpoint cooling
• Enable / disable shelter comfort mode, which is 21°C in shelter and low fan speed/noise.
• Change setpoint heater
• AC1& AC2 enable/disable
• AC1& AC2 Lead/lag enable/disable. This function will swop set points on AC1 & AC2 every
second time the AC are operated
• Diagnostics mode, which checks every component connected. See more in unit manual
• Alarm status which indicates which component is faulty. Each number inform which com-
ponent is faulty. Error numbers are product specic. See more in unit manual.
Follow the display leaet for guidance for usage of the display.
The controller has an integrated SD card reader that can exchange parameters for informa-
tion and editing.
The SD card will overall do two operations:
1.Store operation logging data, if an SD card is present. By default the ComboCooler will
log a complete set of operation data once each minut.
If suspecting an operation error, place the SD card into the ComboCoolers SD slot, wait
some minutes, and move the SD card to a computer, where the le can be read with word-
pad or simular.
2.Changing parameters. Place an empty SD card in the reader, and the controller stores
the parameter conguration immediately on the card (cc4_cfg.txt)
A.Remove the SD card, place it in a computer, and open the le with wordpad or simular.
B.Edit the parameter needed, without changing any amount of empty spaces. End by
saving the le with the exact same le name.
C.Place the SD card in the combo, and the new conguration will be loaded and initiated
on the y. No need to reboot.
For a complete guide on changing parameters via SD card, please obtain the advanced CC4
manual, available by request.
Main interface
options
Display unit
(accessory)
SD card
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Installation
The ComboCooler unit needs proper installation in order to operate awless for many years.
Please follow this section for installation
• Never carry out any installation, maintenance or service, without disconnecting the power
supply (please notice that this units has dual power source AC & DC), by means of the
external power supply disconnecting devices.
• NEVER lift the unit by hands- use only forklift or similar hoisting device
Unpack and prepare unit for mounting:
Step Action Illustration
1
Remove both side panels
1.Lift side
2.Pull outwards
3.Pull out in lower part
4.Pull sideways down
1
2
3
1 1
2
2
4
8 mm
4 mm
3 mm
4x DIN 10
2
Remove lower air grill
1.Push both sides
2.Pull downwards
1
2
3
1 1
2
2
4
8 mm
4 mm
3 mm
4x DIN 10
3
1.Remove mounting frame
2.Remove the two M10
bolts each side of the
unit.
1
2
3
1 1
2
2
4
8 mm
4 mm
3 mm
4x DIN 10
Introduction
WARNING
Warning
Caution
Preparation
12

Installation, continued
Please reserve exempted space for service as shown below.
400 mm 400 mm
1440 mm
Fig. 6
Please make sure, that one of the two shown cable run options is achievable.
Standard option - needs
drilling holes in wall in
center to the units holes
Alternative option- route the
cable in free air space if needed
Fig. 7
Pre-installation
considerations
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Installation, continued
Cut two retangular holes with appropiate tools, according these below measures
Please consider drilling the correct amount of cable inlets.
min. 925 mm
optimum 1125 mm
or more
500 mm
323 mm
275 mm
min. 90 mm
800 mm
800 mm
364 mm
25 mm
30 mm
30 mm
Drill only cable
inlet if needed
Fig. 8
Fasten the frame to the wall, with minimum 8 pcs. appropiate screws
4 mm
min 8x
4x DIN 10
Fig. 9
Cut-out
Warning
Caution
Mount bracket
14

Installation, continued
Place the unit onto the bracket by means of a forklift or similar lifting device.
4 mm
min 8x
4x DIN 10
Fig. 10
Mount the four bolts, securing the unit to the frame, and seal the edges between unit and
wall according illustration
4 mm
min 8x
4x DIN 10
Fig. 11
Mounting unit onto
bracket
Secure and seal
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Installation, continued
Route the room sensor to an indoor location, where the temperature wants to be controlled.
Please make sure the sensor isn’t blocked or touching any metal, and isn’t placed in the air
stream coming from the ComboCooler.
Fig. 12
Please pull cables from inside, through wall opening, and following the path shown.
Fig. 13
Indoor sensor
Route and secure
cables
16

Electrical connections
This below illustration shows the pin assignment for connections:
J1
J5
J9
J4
J16
J17
J6
J11
J10
J15
J7
J3
J2
AL 1
AL 2
AC 1
AC 2
RS485 in
RS485 out
TTL
1=Gnd
2=B
3=Gnd
4=A
5-8=nc
1=Gnd
2=B
3=Gnd
4=A
5-6=line pwr gnd
7-8=12v line pwr
PC interface - galvanic isolated
Gnd
Room sensor
Gnd
Digital input 2
Gnd
Digital input 1
Alarm 2
Alarm 2
Alarm 1
Alarm 1
AC 2
AC 2
AC 1
AC 1
Damper 2 GND
Damper 2 close
Damper 2 open
SD reader
48V DC negative
48V DC positive
48VDC
16A fused
External safety breaker
(not included)
-t°
Pre wired
See unit schematics
Comp. out 1
Comp GND
Damper 1 open
Damper 1 close
Damper 1 GND
Heater out +
Heater out GND
Condenser fan out +
Condenser out GND
Amb temp sens
Amb temp sens GND
Supply temp sens
Supply temp sens GND
Condenser temp sens
Condenser temp sens GND
Phase monitor input
Phase monitor input GND
Filter guard input
Filter guard input GND
Door switch input
Door switch GND
1: Fan positive
2:Fan PWM
3:Fan tacho
4:Fan GND
1: Fan positive
2:Fan PWM
3:Fan tacho
4:Fan GND
1: Fan positive
2:Fan PWM
3:Fan tacho
4:Fan GND
Standard shielded ethernet cable
(568A termination both ends)
Accessory
10A Mini blade terminal.
FX ”Littlefuse” type ”997 010”
10A Mini blade terminal.
FX ”Littlefuse” type ”997 010”
10A Mini blade terminal.
FX ”Littlefuse” type ”997 010”
SD card slot for setup and logging
Green LED
Red LED
F2
F3
F4
0 / 12V DC with pull up
Potential free -max. 42VAc or 60VDc. /
500mA - (SELV)-Default normally open -
jumper changeable
48V DC/100mA
SD card slot for setup and logging
PC interface - galvanic isolated
48VDC
16A fused
Green LED
Red LED
Accessory
Standard shielded ethernet cable
(568A termination both ends)
48V DC negative
External safety breaker
(not included)
48V DC positive
Fig. 14
External
connections
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Electrical connections, continued
This below table describes in details the connections on“Fig. 14” on page 17, used when
connecting external items.
Input Description
J1 –power input The power supply input accepts 40-60V DC and has an isolated potential
to earth (cabinet parts). This means that the input even accepts -48V DC.
Just connect positive to positive, and negative to negative. The input
needs external connected 16A circuit breaker.
If input is below 40V DC the unit stops operation, and goes into power
save mode, in order to prioritize power to the telecom services. Power
save mode can activate an alarm.
J5 -room sensor Temperature sensor input supporting NTC resister type: Vishay NT-
CLE100E3272GB0.
Resistance:
8790Ω @ 0°C. / 3372Ω @ +20°C. / 1439Ω @ +40°C.
J5- digital input For use with external dry contacts (max.10mA @ 12V). Input is congur-
able to“Normally open”or“Normally closed” by changing parameters.
This input can force a specic operation, for instance shutting down the
cooling system, and close the damper in case of a re.
J5- alarm 1 / 2
outputs
Dry contact, rated 0,5A@60Vdc – “Normally Open” or “Normally closed”
jumper changeable. Operation alarms can be routed in the SW param-
eters list, to either output 1 or 2.
J5 – AC 1 / 2 Dry contact, rated 0,5A@60Vdc – “Normally Open” or “Normally closed”
jumper changeable for connecting external air conditioners
Examples of usage, see
J15 – HEAT J15 is located on the rear edge of the PCB.
Toggles from 0Vdc to 40-60Vdc / 300mA max
J4 - damper 2 The damper output feeds the damper motor with 40-60Vdc/ max. 100mA
J16 / 17 - RS 485 RS485 – RTU Modbus.
J17 can supply the Dantherm display unit with power.
Communication data:
baud rate - 9600
data bits - 8
parity - none
stop bits - 1
ow control - none
The MODBUS device ID can be set in the parameter list.
J6 – TTL TTL to PC interface. Used to change parameters in real time
Communication data:
baud rate - 9600
data bits - 8
parity - none
stop bits - 1
ow control - none
SD card reader For uploading new parameter set. Supports up to 32GB SD card
Connection
description
18

Alarm out
In order to create the correct functionality on any hardwired alarm/digital in connections, the
corresponding parameter, needs to be set up correct.
After connecting the wires to the output terminals, please enter the parameter setting
through the SD card. See more in section “SD card” on page 1111
Under the system, control conguration menu you will nd these settings:
Alarm Mapping 1.Alarm1 2.Alarm2
1.Pwr Save Mode [PSM][0/1]: 1 0
2.Room Temp H/L [THL][0/1]: 1 0
3.Fan 1 [F1][0/1]: 1 0
4.Fan 2 [F2][0/1]: 0 0
5.Fan 3 [F3][0/1]: 0 0
6.Onbrd. Sens [OS][0/1]: 0 0
7.Room Sens [RS][0/1]: 1 0
8.Amb. Sens [AS][0/1]: 1 0
9.Supp. Sens [SS][0/1]: 0 0
10.Cond. Sens [CS][0/1]: 0 0
11.Digi.1 I/P [FIL][0/1]: 0 0
12.Digi.2 I/P [FI][0/1]: 0 0
13.Door Xtch I/P [DI][0/1]: 0 0
14.Filt Grd I/P [FI][0/1]: 0 1
15.Phase I/P [FI][0/1]: 0 0
In these default values above, its shown that:
• The lter guard is routed to activate alarm 2 output
• Selected other alarms are routed to alarm 1 output.
If any of the alarms need to be changed, please follow the for SD card usability guide in sec-
tion“SD card” on page 11
If the default “normally open” alarm state is to be changed to“normally closed”, please locate
and change the jumper illustrated in section“External connections” on page 17
Introduction
Alarm out routing
Changing alarm
routing
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Digital inputs
After connecting of the wires, to the input terminals, please initiate parameter settings
through SD card.
Both digital inputs can control and force a certain operation or request. These are some of the
possibilities:
• Shutting down in case of a re.
• Shutting down in case of service inside the shelter.
• Route other alarms from external equipment (FX AC unit) through the digital input to the
controllers alarm output
• Force external heat on/o
• Force external AC on/o
In all conguration menu sections, the digital input functionality is controllable.
Cooling Fan Conguration Fan 1 Fan 2 Fan 3
18.Override - Digi.1 [x/0-100]: 0 :x :x
19.Override - Digi.2 [x/0-100]: x :x :0
In these default values three option exist:
• Parameter X=doesn’t change the current operation statew
• Parameter 0=force OFF (e.g. in case of re)
• Parameter 1-100 =force duty cycle to a value between 1-100
The setting for normally open or normally closed for the inputs is set in the “congure system
parameter” section in the parameters le as well.
15.Dig.1 NO/NC Type [Dig1][0/1]: 0
16.Dig.2 NO/NC Type [Dig2][0/1]: 0
Digital input
20