Pfannenberg DTS 3000 Series User manual

Technical Manual
Operation and installation cooling units
DTS 3000 SERIES 115V / 230V / 460V
Version 1.0, November 2018

Page 2 | OPERATING MANUAL DTS Return To Table Of Contents
Preface
The skills and information provided in the ORIGINAL OPERATING MANUAL are required for assembly and safe operation of
Pfannenberg’s DTS 3000 Series Cooling Units.
The information is presented in a brief, clearly arranged format. The chapters are numbered throughout. If you have the
operating manual in digital format, the links are interactive.
Various unit types are documented in this operating manual.
Pfannenberg cooling units are subject to continuous improvement. Please understand that we reserve the right to make
changes to the design, equipment and technology. For this reason, no claims to specific features of the unit can be derived
from the content of this operating manual.
Safety Instructions and Symbols
DANGER
Identifies an exceptionally hazardous situation. Severe, irreversible injuries or death will occur if this notice is not observed.
WARNING
Identifies an exceptionally hazardous situation. Severe, irreversible or deadly injuries could occur if this notice is not observed.
DANGER
Identifies an exceptionally hazardous situation in connection with electrical voltage. Severe, irreversible injuries or death will
occur if this notice is not observed.
Digital operating manual:
If you have the operating manual in digital format, the links are interactive.
Clicking on links takes you to the target text position.
• The table of contents is also interactive.
• The key combination ALT fbrings you back to the starting point.
Identifies a hazardous situation. Minor or moderate injuries could occur if this notice is not observed.
Notice is used to address practices not related to physical injury.
CAUTION
NOTICE

OPERATING MANUAL DTS | Page 3
Return To Table Of Contents
Table of contents
1 : INTENDED USE
1.1 General overview.......................................................................................................................................... 4
1.2 Duty of the operator ..................................................................................................................................... 4
2 : UNIT DESCRIPTION
2.1 Description of use......................................................................................................................................... 5
2.2 Scope of delivery.......................................................................................................................................... 5
2.3 Order options ............................................................................................................................................... 5
2.4 Functional description................................................................................................................................... 5
2.4.1 Air flow functional principle ................................................................................................................... 5
2.4.2 Temperature Regulation ....................................................................................................................... 6
2.4.3 Safety Concept .................................................................................................................................... 6
2.5 Type plate..................................................................................................................................................... 7
2.6 Technical data and spare parts..................................................................................................................... 8
3 : ASSEMBLY AND INITIAL COMMISSIONING
3.1 Transport...................................................................................................................................................... 8
3.2 Storage ........................................................................................................................................................ 8
3.3 Unpacking.................................................................................................................................................... 9
3.4 Assembly ..................................................................................................................................................... 9
3.4.1 General assembly requirements ........................................................................................................... 10
3.4.2 DTS cooling unit assembly (side attachment)........................................................................................ 10
3.5 Electrical connection..................................................................................................................................... 12
3.5.1 Standard controller (SC) electrical circuit diagram................................................................................. 12
3.5.2 Door contact switch............................................................................................................................. 12
3.5.3 Main supply connection. ...................................................................................................................... 13
4 : OPERATION
4.1 General functions ......................................................................................................................................... 17
4.2 Operation of the cooling unit......................................................................................................................... 17
5 : SERVICE AND MAINTENANCE
5.1 General cleaning........................................................................................................................................... 18
5.2 Maintenance................................................................................................................................................. 19
5.3 Maintenance checklist template.................................................................................................................... 20
5.4 Decommissioning......................................................................................................................................... 21
6 : TROUBLESHOOTING.................................................................................................................................. 22
6.1 LED Status Sequences................................................................................................................................. 23
7 : ACCESSORIES .............................................................................................................................................. 24
8 : TERMS OF WARRANTY............................................................................................................................. 24

Page 4 | OPERATING MANUAL DTS Return To Table Of Contents
1 : INTENDED USE
1.1 General overview
The Pfannenberg attachment and installation cooling units of the DTS series are stationary cooling units for the dissipation of
heat from switch cabinets.
The cooling units have different cooling outputs. For exact specifications power consumption, see Technical data. Use of
aluminum filters, fleece filters and fluted filters is possible with an additional adapter.
The cooling units are available with thermostat controllers. These controllers are regulating units for the adjustment of
refrigeration functions and operating data.
• For detailed specifications for the controller, see Technical data and Operation.
All Pfannenberg cooling units are ROHS-compliant and free from:
• Silicone connections
• PCT, asbestos, formaldehyde, cadmium
• Moisture-impairing substances
1.2 Duty of the operator
The operator must ensure that the cooling units are used exclusively as intended and dangers of all types to the life and
limb of users or third parties are avoided. In addition, accident prevention regulations and recognized safety rules are to be
observed.
The operator must ensure that all users have read and understood this operating manual. Non-observance of this operating
manual will void the warranty. The same applies if improper work has been carried out on the unit by the customer and/or
third parties without the approval of the manufacturer.

OPERATING MANUAL DTS | Page 5
Return To Table Of Contents
Spare parts from third-party manufacturers can damage the unit
• Only original parts are subject to the manufacturer’s quality control.
• Only use originally manufacturer parts for safe and reliable operation.
• For Pfannenberg spare part numbers, see Technical data.
• For Pfannenberg part numbers for accessory orders, see Ordering of accessory parts.
WARNING
2 : UNIT DESCRIPTION
2.1 Description of use
Pfannenberg DTS series cooling units are designed to dissipate heat from switch cabinets. Sensitive components in the
switch cabinet are protected.
2.2 Scope of delivery
The shipment consists of the following contents:
• DTS cooling unit
• Cooling unit quick guide
• Accessory kit: Appropriate seal, fastening material, electrical plug connector, etc. for the specific unit type
• Special accessories, if applicable
2.3 Order options
Hazardous due to impermissible use of units
Inappropriate use of the units can cause severe accidents.
• Cooling units must only be used in stationary operation.
Pfannenberg cooling units are only approved for stationary operation. As cooling units with protection rating IP 54, the cooling
units are essentially dust-protected. Limitation: Dust can still penetrate after continuous exposure. The cooling units are resis-
tant to spray water, but not a constant water jet.
NOTICE
2.4 Functional description
2.4.1 Air flow functional principle (See Section 2.6 for Each Unit Type)
Danger due to the release of very warm air.
• The air outlet can become very warm.
• Keep body parts away from the air outlet.
• For the ambient temperature and air outlet ratio, see Technical data.
CAUTION

Page 6 | OPERATING MANUAL DTS Return To Table Of Contents
2.4.2 Temperature Regulation
WARNING
Hazards due to modified safety equipment
Non-functioning or defective safety equipment can cause severe accidents.
• Any changes to the unit, particularly the safety equipment, are prohibited.
• In case of defective safety equipment, shut down the unit and decommission it immediately.
• Fans and compressors are protected from overloading and overheating.
2.4.3 Safety concept
The thermostats are for the adjustment of refrigeration functions and operating data.
DTS 3041/3061/3081
DTS 31XX/32XX/34XX/36XX
DTS 3021/3031

OPERATING MANUAL DTS | Page 7
Return To Table Of Contents
Hazards due to noncompliance with manual
Disregarding type plate specifications can result in severe accidents.
• Always observe the specifications on the type plate when installing and maintaining the units.
• The figure shows the standard version of type plate.
WARNING
2.5 Type plate
Item
Number Designation Item Number Designation
1 Manufacturer logo 11 CE mark
2 Unit type 12 UL mark
3 Part number 13 QR code
4 Serial number 14 Coolant pressure
5 Rated operating voltage 15 Exterior / interior ambient conditions
6 Frequency 16 Cooling capacity
7 Nominal current 17 Coolant
8 Power rating 18 Global Warming Potential
9 Fuse 19 CO2 equivalent value
10 Protection type
1
2
11
17
19
13
12
3
4
6
5
9
7
8
1015
14
16

Page 8 | OPERATING MANUAL DTS Return To Table Of Contents
2.6 Technical data and spare parts
Technical data, spare parts, and cutouts can be found on our website here:
http://pfannenbergusa.com/thermal-management-downloads/
Hazards due to uncontrolled movements
Improper securing of the unit can result in severe accidents.
• Loading must only be carried out by trained, qualified personnel.
• Lash the unit correctly for transport on a truck or trailer.
• Only use lashing straps with an adequate rated strength.
• Use slip-resistant materials for securing, e.g. anti-slip mats.
• When loading by crane, do not walk or stand under the raised units.
WARNING
Danger of material damage during transport and setting down of the units.
• Improper device securing or uncontrolled movements can cause damage.
• Exercise maximum caution during movement and transport of the units.
Always transport the cooling units using the packaging provided by the factory.
Transporting cooling units
REQUIREMENTS:
• Cooling units must be in the packaging provided by the factory.
• Unit must be in the upright position.
REQUIRED TOOLS AND MATERIAL:
• Lashing straps, loading crane, if applicable
PROCEDURE:
• Always raise cooling units by the housing.
• Always raise cooling units slowly and evenly and set down safely.
• Secure correctly for transport with lashing straps.
• The cooling unit was transported and loaded correctly.
3.2 Storage
• Do not expose the cooling unit to temperatures above +70 °C during storage*.
• Unit must be in the upright position.
* The warranty will no longer apply if these instructions are not observed.
3 : ASSEMBLY AND INITIAL COMMISSIONING
3.1 Transport
NOTICE

OPERATING MANUAL DTS | Page 9
Return To Table Of Contents
WARNING
Hazard of accidents due to the heavy weight of the units
Uncontrolled movements of the units during assembly can cause accidents.
• Use suitable lifting equipment and secure units to prevent accidents.
• Also secure assembled components.
3.3 Unpacking
NOTICE
• Perform a visual inspection for transport damage when unpacking the cooling units. Take note of any loose parts,
dents, scratches, visible loss of oil etc.
• Inspect and secure the packaging mtaterial for any loose functional parts before disposal.
• Report any damages to the freight carrier immediately. Observe the “Terms for Cases of Damage”.
• Precise information about defects, including possible photos must be provided for the handling of warranty claims.
Always specify the type designation and serial number.
Hazard of injury due to sharp edges
• For manufacturing reasons, the metal edges of the unit may have burrs.
• Wear gloves during service and assembly work.
CAUTION
3.4 Assembly
Life-threatening hazard due to electric shock
Live units and exposed connection cables can generate an electric shock and cause severe accidents.
• Work on electrical connections must be carried out exclusively by trained, qualified electricians.
• Before assembly, de-energize all supply lines to the separate fuse or a main switch, disconnect the system and secure to
prevent re-connection.
• Test to ensure the absence of voltage on the unit.
DANGER
Hazard of crushing during assembly of the unit
There is a hazard of crushing between the switch cabinet and frame of the unit during assembly.
• Keep body parts out of the space between the frame and unit cut-out.
• Work carefully and wear gloves.
CAUTION
Switch cabinet installation hazard due to assembly chips
When making the cooling unit cut-outs, assembly chips can fall into the switch cabinet.
• When assembling the switch cabinet, protect against contaminants and use protective covers.
NOTICE

Page 10 | OPERATING MANUAL DTS Return To Table Of Contents
3.4.2 DTS cooling unit assembly (side attachment)
Make cut-outs for the DTS cooling unit
REQUIREMENTS:
• All general requirements have been fulfilled; see General assembly requirements
• The unit is de-energized
REQUIRED TOOLS AND MATERIAL
• Saw
• Use a switch cabinet cutter, if applicable
• Protective covers
PROCEDURE
• Use a protective cover to protect the switch cabinet from chips.
• Provide the switch cabinet with cut-outs and holes. For the prescribed dimensions, refer to the figure exterior view of the
switch cabinet.
• Deburr the cut edges.
• Remove chips and assembly waste from the switch cabinet.
• Cut-outs and holes have been made.
3.4.1 General assembly requirements
• Select an assembly location for the switch cabinet which will guarantee adequate ventilation of the cooling unit. A minimum
clearance of 200 mm between units and the nearest wall must be observed.
• Installed components in the switch cabinet must not impede air circulation.
• Protect the installation location from heavy contamination with covers.
The following general requirements must be followed for safe and reliable operation of the cooling units:
• Secure the switch cabinet against tipping.
• Ensure that provided hinges can support the additional weight of the cooling unit.
CAUTION

OPERATING MANUAL DTS | Page 11
Return To Table Of Contents
Hazard of accidents due to incorrectly installed seals
Leaky seals can allow moisture to penetrate and cause short-circuits.
• Install the seal so that it provides a tight seal to the switch cabinet.
• Always inspect seals during cleaning and maintenance.
Install seal on the DTS cooling unit (side attachment)
Install seals and assembly
REQUIREMENTS:
• Cut-outs for the DTS cooling unit have been made; see section 2.6 for each unit.
• The cooling unit is de-energized.
REQUIRED TOOLS AND MATERIAL
• Installation tool
• Accessory kit: Threaded bolts, screws, nuts, washers
PROCEDURE
• Attach seals on the DTS unit. Fit the seals with the slotted holes over unit mounting holes.
• Screw in the two supplied threaded bolts (accessory kit) in the upper fastening points of the DTS cooling unit. Suspend the
cooling unit on the switch cabinet with the threaded bolts installed from outside. Tighten the screws on the DTS cooling unit
on the switch cabinet interior. Use the supplied screws, nuts and washers (accessory kit) to fasten the unit. Firmly tighten the
screw fasteners so that the seal is pressed together.
• The DTS cooling unit is attached to the switch cabinet and ready for electrical connection; see Electrical connection.
DANGER

Page 12 | OPERATING MANUAL DTS Return To Table Of Contents
3.5.2 Door contact switch
Hazard due to connection of external voltage at the input of the door contact
External voltage can cause severe accidents.
• Connection of external voltage to the input for the door cabinet is prohibited.
Installation of a door contact switch increases safety and prevents increased accumulation of condensate.
• If a door contact switch has not been connected, the connection contact (S1) must be jumped.
Door contact switch installation
REQUIREMENTS:
• The cooling unit is de-energized.
PROCEDURE:
• The door contact switch is connected to the X54 connection at 3 & 4 or the electrical circuit diagram in the housing cover.
• The door contact is supplied with high voltage, from the cooling unit on the DTS 3021/31/31 SS and 30X1 series units.
• The door contact is supplied with low voltage from the control board on the DTS 31X1, 31X5, 32X1, 32X5, 34X1 and 36X1
series units.
• The door contact switch is connected. The motors switch off when the switch cabinet is opened.
WARNING
Life-threatening hazard due to electric shock
Live units and exposed connection cables can generate an electric shock hazard and cause severe accidents.
• Work on electrical connections must be carried out exclusively by trained, qualified electricians.
• Ensure that the unit is voltage-free before routing all electrical connections.
3.5 Electrical connection
3.5.1 Standard controller (SC) electrical circuit diagram
DANGER

OPERATING MANUAL DTS | Page 13
Return To Table Of Contents
WARNING
Potential hazard due to incorrect cables
An incorrect cable cross-section will cause the cable to overheat. Scorched insulation can cause fires.
• The cable cross-section (4) matches the output required for the power consumption and is 1 – 2.5mm² or AWG 18 to AWG 14.
DANGER
3.5.3 Main supply connection
Electric arcing can cause electric shock and burns.
When disconnecting and connecting the plug connector for mains connection under load or voltage, electric arcing,
dangerous voltage and electric shock can occur.
• The plug connector for mains connection must never be plugged in or disconnected under load/voltage.
• Work on plug connectors must only be carried out with adequate lighting.
• Always disconnect power to unit.
The following general requirements must be ensured for safe and reliable operation of the cooling units:
• Upstream installation of a supply-side temperature regulator is prohibited.
• Connect the upstream fuse specified on the type plate as wiring protection; see Type plate.
• Ensure that the type plate specifications for rated values match the present values for mains voltage and mains frequency;
see Type plate.
• Always connect the cooling unit to the mains by means of a separating device (switch/contactor).

Page 14 | OPERATING MANUAL DTS Return To Table Of Contents
Life-threatening hazard due to electric shock
Circuit breaker systems that are not connected or attached incorrectly can generate hazardous voltages and electric shock
and cause severe accidents.
• Work on electrical connections must be carried out exclusively by trained, qualified electricians.
• Circuit breakers systems must be provided in accordance with DIN EN 60204-1, chapter 8.2.
• Each element of electrical equipment must be connected to the circuit breaker system.
• Never interrupt the circuit breaker system if electrical equipment is attached to covers, doors or cover panels.
• If parts are removed, e.g. for maintenance work, ensure that the circuit breaker system is not interrupted for the remaining parts
Cooling unit electrical connection
DANGER
Connector
Strain Relief Ø6...10 / Ø10...14 Ø13...18
Conductor PE N,L PE N,L
Dismantling Length y (mm) 30 25 55 50
Dismantling Length y (splitter connector) 45 40
Insulation Strip Length x (mm) 8
(conductor cross section 1,5 ... 4 mm2)
Screw Connections
115V 230V 230V 460V 460V
1 L L L L1 L1
2 N N L L2 L2
3 ----- ----- ----- ----- L3
PE
Refer to Connection Diagrams:

OPERATING MANUAL DTS | Page 15
Return To Table Of Contents
Opening the Connector
Closing
Wire Connection
Plugging and Locking
1
2
Detail
Screw connection:
Drive PZ1,
Tightening torque
typ. 0.5 Nm
Screw connection:
Tightening torque
typ. 4+1 Nm
Clicks into place
Clicks into place
1
2
Clicks into place
Part Description: Connection Instruction

Page 16 | OPERATING MANUAL DTS Return To Table Of Contents
Requirement
• All general requirements for safe and reliable operation are assured; see Main supply connection.
• The cooling unit is de-energized.
Procedure
• Connect the cable with the connecting plug (accessory kit) as specified in the electrical circuit diagram; see Electrical
connection.
• For electrical connection, insert the screwdriver into the cage terminal and connect the cables to the cooling unit with the
connecting plug .
• Insert the screwdriver firmly into the cage terminal. Never twist the screwdriver; otherwise the cage terminal
will be damaged.
• Before switching on, ensure that the mains voltage matches the upstream fuse; see Electrical connection.
.
• The cooling unit is connected electrically.
CAUTION
To maintain the IP-rating type of enclosure, protective caps (accessory) must be mounted on all unoccupied connectors!
Further the connectors must not be exposed to bending forces (e.g. do not attach loads to the cable, no free-dangling cable
windings etc.). The connectors are not suitable for current interrupting. Never connect or disconnect under load!

OPERATING MANUAL DTS | Page 17
Return To Table Of Contents
Danger of damage to the cooling unit
Operation without the unit cover prevents the adequate supply of air to the condenser and limits the intended heating function.
• Only operate the cooling unit with the unit cover installed.
• Once assembly and installation work is completed, switch on the power supply to the cooling unit.
• After the supply voltage has been connected and the door is closed, the units run continuously.
• The cooling unit is equipped with an electronic control unit. A temperature sensor detects the temperature of the air sucked
in from the interior of the switch cabinet.
• If the upper or lower limit temperature is exceeded or undercut, a fault indication is triggered.
• The ambient conditions and switch cabinet interior temperatures must correspond to the prescribed technical data; see
Technical data.
• The ambient temperature must be less than 55°C (45°C for the DTS 3021/3031/3031 SS & 3041).
4 : OPERATION
4.1 General functions
NOTICE
4.2 Operation of the cooling unit
• After connection of the mains voltage, the device switches to operating mode.
• If cooling mode as needed; this will take place depending on whether a temperature switching threshold (TSet) is reached or
undercut.
• Cooling mode switches off when the temperature switching threshold (TSet) is undercut.
• The evaporator fan (internal), condenser fan (external) switch off when the door is opened.
Operating conditions
• The mains voltage must lie within the specified range; see Electrical data.
• A deviation of ± 10 % is permissible.
• The ambient temperature must be below 55 °C (45°C for the DTS 3021/3031/3031 SS & 3041). For further options, see
Technical data.
• The cooling unit must only be used in such a manner as to ensure that the specified cooling capacity is able to meet actual
demands.
• Only the specified coolant may be used.

Page 18 | OPERATING MANUAL DTS Return To Table Of Contents
Life-threatening hazard due to electric shock
Live units and exposed connection cables can generate an electric shock and cause severe accidents.
• Work on electrical connections must be carried out exclusively by trained, qualified electricians.
• Before working on the unit, de-energize all supply lines to the separate fuse or a main switch, disconnect the system and
secure to prevent re-connection.
• Test to ensure the absence of voltage on the unit.
5 : SERVICE AND MAINTENANCE
5.1 General Cleaning
WARNING
CAUTION
DANGER
Hazards of accidents due to component damage during cleaning
Cleaning of cooling units with water jet, steam jet, high-pressure washer or sharp objects can damage the electrical and
electronic assemblies. Malfunctions can cause accidents.
• Do not clean with a water jet, pressure washer or flammable cleaning agents.
• Protect electrical components from the penetration of moisture.
• Do not use pointed or sharp-edged objects to clean the fins. They must not be pinched or damaged.
Hazards of crushing during removal of the unit cover
Hands and other body parts can be crushed during removal and re-installation of the unit cover.
• Keep body parts out of the space between the frame, springs and unit cut-out.
• Work carefully and wear gloves.
The frequency of cleaning intervals depends on the operating conditions in the individual case. The following cleaning work
must take place regularly for safe and reliable operation of the cooling units:
• Remove dust or environmental residue from the heat exchangers.
• Check the condensate drain regularly.

OPERATING MANUAL DTS | Page 19
Return To Table Of Contents
Life-threatening hazard due to electric shock
Live units and exposed connection cables can generate an electric shock and cause severe accidents.
• Opening, troubleshooting and replacement of components on the unit must only be carried out by qualified personnel.
• Always ensure that the unit is de-energized before working on the unit.
WARNING
WARNING
DANGER
5.2 Maintenance
Hazard due to improper maintenance work
Damage of components and faulty replacement of components can cause accidents.
• Always switch off the disconnector/contactor before beginning maintenance work.
• Wait For unloading phase of 5 minutes for the electric components. Open only afterwards device.
• Ensure that the fans are in idle position and are no longer rotating.
• After replacement of defective parts or components, inspect the unit for correct and safe operation.
• After all maintenance or replacement of spare parts, check to ensure the full capability of the condensate drain.
Spare parts from third-party manufacturers can damage the unit and cause accidents.
• Only original parts are subject to the manufacturer’s quality control.
• Only use specially agreed manufacturer parts for safe and reliable operation.
Danger of unit damage due to incorrectly performed maintenance
Disregard of the recommended maintenance work reduces the cooling capacity of the cooling unit and could result in
reduced machine availability.
• Maintenance work must be carried out regularly, as specified in the maintenance checklist.
• Warranty claims are only valid for units that have been maintained according to specifications.
Pfannenberg recommendation to the operator for maintenance work:
• Carry out maintenance work regularly, every 12 months, according to the maintenance checklist; see Maintenance checklist
template.
• Shorter maintenance intervals are required for cooling units that cool in oil- and dust-laden ambient air. A reduced guideline
value of two to six months between maintenance intervals applies.
NOTICE

Page 20 | OPERATING MANUAL DTS Return To Table Of Contents
* Maintenance intervals are more frequent, depending on the degree of contamination.
5.3 Maintenance checklist template
Maintenance Interval:
• Conduct maintenance every twelve months.
• Conduct maintenance every two to six months
in oil and dust-laden environmental air.
Type:
Serial number:
Date of maintenance:
Technician:
Cooling Unit Maintenance Checklist
Unit range designation/
Required maintenance tasks
Visual
inspection To Do Result
1Aggregate before maintenance
1.1 General visual inspection of the aggregate
1.2 Inspection for corrosion damage
2Condenser / heat exchanger
2.1 Inspection for general corrosion damage
3Condenser fan (external)
3.1 Inspect mount for loose parts
3.2 Inspect the electrical connection for damage
3.3 Check motor bearings for noises
3.4 Check the drive for signs of overheating
4Evaporator fan (internal)
4.1 Inspect mount for loose parts
4.2 Inspect the electrical connection for damage
4.3 Check motor bearings for noises
4.4 Check the drive for signs of overheating