Pfannenberg DTI 9021, DTFI 9021, DTS 9011H Manual

Hints on the manual

Read this manual completely and carefully before installing the unit.
This manual is an integral part of the scope of delivery and must be kept until the unit is disposed of.

This handbook contains instructions for the installation and operation of

• Door and side-mounted,built-in Cooling Units, Series DTI/DTFI
• Door and side-mounted,bolt-on Cooling Units, Series DTS

Hint
The technical specifications for each machine along with additional information on assembly, connections and operation are contained in a separate sheet.
In this manual, safety recommendations and other information are structured as follows:

Hazard!
If the measures described in the following are not strictly observed there is danger to life and health.

Hazard!
If the measures described in the following are not strictly observed there is danger to life and health due to electrical shock.

If the measures described in the following are not strictly observed material damage may be caused.

Hint
A hint contains additional information on the action or instruction described.

Handling

Transport

1. Lift cooling unit by the casing only.
2. Transport the cooling unit only in condition of usage.

Failure to observe these instructions will render the warranty provisions null and void.

Storage

• Never expose cooling units to temperatures exceeding +70°C during storage.
• Store cooling unit only in condition of usage.

Failure to observe these instructions will render the warranty provisions null and void.

Unpacking

• Prior to and during unpacking make a visual inspection of the cooling unit to see whether any damage has occurred during transport. Especially pay attention to loose parts, dents, scratches, visible loss of oil etc.
  Any damage must be reported immediately to the forwarding agent (follow the instructions in "Rules for Damage Claims"). Moreover, the latest edition of the "General Conditions for Sup plies and Services" issued by the ZVEI ( Central Association for the German Electrotechnical Industry") shall apply.
• Before disposing of packing material ensure that it does not contain any loose components.

Burr caused by production may be present on the metal edges of the unit. Always wear protective gloves when carrying out maintenance work and installation.

In case of a warranty claim exact details on the fault (photograph, if possible) and the indication of type and serial number of the cooling unit are required.

Scope of delivery and options

Scope of delivery

The Scope of delivery includes:

• cooling unit (with connection for door contact switch)
• Enclosed package (among other things sealing profile, fastening material, electrical plug-type connectors)
• special accessories, if applicable.

Options

• Options on request or in accordance with the catalogue.

General Information

• Old devices can be properly disposed of by Pfannenberg. They must be sent to one of our works shipment/postage paid.
• All cooling units produced by Pfannenberg are free from
  • silicone compounds,
  • PCB,
  • PCT,
  • asbestos,
  • formaldehyde,
  • cadmium,
  • substances impairing wetting.
• Every cooling unit is checked to ensure that it is tight according to the provisions of UVV-BGV D4 (German regulations covering accident prevention).
• Prior to delivery the electrical safety of every cooling unit is factory tested. This means that, in accordance with UVV-BGV A2, §5 (4), the operating company is released from the obligation to arrange for a test of the electrical part of the cooling unit before initial start of operation.

ID Plate and Technical Data

For installation and maintenance, note the data on the ID plate; it is to be found on the back of the cooling unit casing The technical details applicable to the cooling unit are in the supplement.

Safety

Cooling units produced by Pfannenberg are designed for dissipating heat from switch cabinets (IP 54). During each cooling process condensate can be produced. The cooling unit is only suitable for stationary operation.
The cooling unit may only be used under the ambient conditions specified on the enclosed sheet.
The cooling unit is to a large measure maintenance-free (see Cleaning and Maintenance Section). Every other use is considered as non-authorized use making any warranty null and void.
The electrical equipment must be regularly checked. Any faults such as loose connections or scorched cables must be removed immediately.
Work on the cooling system and on electrical components may only be carried out by authorized specialist personnel.
Compliance with applicable safety and environmental regulations is mandatory.

Hazard!
Isolate the cooling unit from the mains before carrying out any cleaning or maintenance operations.

Only original spare parts may be used.

Function

Principles of function

1. Compressor
2. Heat exchanger (condenser)
3. Expansion device
4. Heat exchanger (evaporator)
5. fan, exterior circulation
6. fan, inner circulation
7. Electronic control system with temperature sensor

The compressor (1) compresses the refrigerant until high pressure is achieved. During this process temperature increases. In the condenser (2) heat is dissipated to ambient air, the coolant becoming liquid. The condenser fan (5) of the condensator takes ambient air in through the condenser, then it releases the air. The pressure of the coolant drops as it passes through the expansion device (3). In the evaporator (4) the coolant absorbs heat from the air in the switch cabinet and evaporates. Thus, the air in the switch cabinet cools down. At the same time the air inside the switch cabinet is being dehumidified. The evaporator fan (6) sucks the air out of the switch cabinet via the evaporator, the cooled air flows back to the switch cabinet. The cooling unit is electronically controlled. For that purpose a temperature sensor records the temperature of the air inside the switch cabinet (7).

The refrigerant is not detrimental to the ozonosphere; it is hardly combustible.

Condensate

During cooling on the evaporator the moisture removed from the air is collected as condensate. In order to avoid any damage to the switch cabinet and the cooling unit, the condensate must be discharged.

The condensate is discharged in the following way:

• In case of normal condensate drainage a reservoir collects the condensate which is then drained by means of a hose.

Always ensure that the condensate is drained properly (safety- drainage).
Excessive condensation can occur if, for example, the switch cabinet is not sealed or if the internal temperature of the switch cabinet is frequently below the dew point.

If there is excessive condensate during normal operation check the sealing of the switch cabinet. We recommend that you install a door contact switch to switch off the cooling unit, when the door of the switch cabinet is opened, in order to prevent excessive condensate.

Installation

General

• The installation place for the switch cabinet must be selected such that proper ventilation of the cooling unit is ensured.
• The single units or the units and the wall must be at a distance of 200 mm at least.
• Air circulation in the switch cabinet must not be impeded by built-in parts.
• The unit must be disconnected from the power supply!
• The site of installation must be protected against contamination.
  
  If the cooling unit is mounted on an switch cabinet door, it must be confirmed that the hinges can support the additional weight or that the switch cabinet will not topple over when the door is opened.
  
  Chips may damage the switch cabinet. If the necessary cut-outs are only made in the switch cabinet when the cooling units are installed, swarf must be prevented from entering the switch cabinet.

Installation of built-in cooling unit DTI

The mounting surface of the switch cabinet is to be provided with cutout(s) and holes for air ventilation openings and for securing the unit according to the accompanying sheet. The drawing on the accompanying sheet also shows the position of the electrical connections and ventilation openings.

1. Make cut-out(s) and drillings for the cooling unit, if not already provided in the switch cabinet (see drawing on accompanying sheet).
   Remove burrs from the cut edges.
   
   1. Cooling Unit DTI
   2. Switch cabinet wall or door

2. Insert the cooling unit (1) into the cut-out from the outside and push through until the unit seal engages with the switch cabinet (2).
3. Fix the cooling unit on the inside of the switch cabinet by means of the M6 nuts (A) provided. Tighten M 6 (D) so that the seal is compressed to a thickness of 2 mm.
4. Remove the device hood (C) in the appropriate direction of movement Y and Z by loosening the screws (B) (do not remove the screws as a safeguard against loss). Remove the earth cable from the hood if necessary.

5. Fit the condensate drain tube to the pipe (see accompanying sheet). Lay the tube with a downward fall. Shorten as required. If the tube has been extended by means of a connector and a further tube, the additional weight of the tube must be appropriately supported so that it does not become constricted.
6. Connect the device hood (C) to the earth cable and then fix to the cooling unit by means of the screws (B).
7. Clamp cables in accordance with the connection diagram (see rear of unit) to the plug-in connectors (enclosed package) and connect to the unit.
   • lead cross-section: 0.5 – 2.5 mm², or AWG20 – AWG14 (for the selection of the cable cross-section the relevant provisions are to be taken into account).
8. Connect the cooling unit to the power source (see Power connection section).

Installation of bolt-on and built-in cooling unit DTS/ DTFI

The mounting surface of the switch cabinet is to be provided with a rectangular cutout as shown on the accompanying sheet. The drawing on the accompanying sheet shows the location of the ventilation openings.

1. Make cutout for the cooling unit, if not already provided in the switch cabinet (see drawing on accompanying sheet). Remove burrs from the cut edges
2. DTFI units: Remove the device hood (C) in the appropriate direction of movement Y and Z by loosening the screws (B) (do not remove the screws as a safeguard against loss) (see accompanying sheet). Remove the earth cable from the hood.
3. DTFI units: Insert the cooling unit (1) into the cut-out from the inside and push through until the unit seal engages with the switch cabinet (2). The snap fastener (3) on the top of the unit will audibly engage and prevent the unit from falling out. DTS units: Glue the sealing (6) on to the cooling unit (5) and position it from the outside to the cut-out in the switch cabinet (2).
   
   1. Cooling Unit DTFI
   2. Switch cabinet wall or door
   3. Securing spring
   4. Condensate drain tube
   5. Cooling unit
   6. Seal

4. Fit the clamping plates (A) and screws included in the component pack and tighten so that the seal is compressed to a thickness of 2 mm.
5. Fit the condensate drain tube to the pipe (see accompanying sheet). Lay the tube with a downward fall. Shorten as required. If the tube has been extended by means of a connector and a further tube, the additional weight of the tube must be appropriately supported so that it does not become constricted.
6. DTFI units: Connect the device hood (C) to the earth cable and then fix to the cooling unit by means of the screws (B).
7. Clamp cables in accordance with the connection diagram (see rear of unit) to the plug-in connectors (enclosed package) and connect to the unit.
   • lead cross-section: 0.5 – 2.5 mm², or AWG20 – AWG14 (for the selection of the cable cross-section the relevant provisions are to be taken into account).
8. Connect the cooling unit to the power source (see Power connection section).

Power connection

• The cooling unit must be connected to the mains by means of a disconnecting device with a contact gap of at least 3 mm when switched off.
• No temperature control must be series-connected to the cooling unit feed. The fuse as indicated on the ID plate must be series-connected as line protection.
  
• Power connection and repairs, if applicable, may only be carried out by authorized trained electricians.

Power supply connection (mains)

Both mains voltage and frequency must correspond to the nominal values indicated on the ID plate of the cooling unit.

Attention: The cooling unit may be damaged if the voltage is too high.
Refers to cooling units for nominal voltages 400 V/440V. As an option, some units, different to the standard (400 V/ 440 V), may be connected to a different mains voltage (For voltage range see enclosed sheet).The feed cables on the transformer primary must be unclamped for this.

Door contact

The door contact is supplied form the cooling unit with an extra- low voltage (<20V, 20 mA).

• In order to avoid any disruptive influences, it is recommended that a sheathed cable with twisted pair leads be used. The screen can be secured on one side to the PE connection point provided on the cooling unit.
• If the use of sheathed cables is not possible, during installation of the cables it must be ensured that they are not routed in the immediate vicinity of potential interference sources (e.g. supply lines, components with relatively high electromagnetic emission).

No external voltage may be applied.
If no door-contact switch is used, the connecting contacts are to be bridged.

Centralised fault indication

For connection of the fault signal line there are 2 connection contacts and/or connecting lines available (see circuit diagram on the Technical Supplementary Sheet¹)
The installation of the fault signal line is not subject to any special requirements.

The contact may be loaded with max. 230 V, 1A.

Operating Conditions

• Voltage must be within ± 10% of the value indicated. Frequency must be within ± 3 Hz of the value indicated.
• Ambient temperature must be below 45°C (for options see supplement).
• Use the unit such that the cooling capacity suits the actual demand.
• Use refrigerant as indicated only.
• Use genuine spare parts only.

Putting into operation and function

General remarks

The cooling unit is provided with an electronic control system. The drawn-in switch cabinet internal air temperature is measured by a temperature sensor. By means of a DIP switch on the control board, different switch cabinet temperatures as well as upper limit temperatures can be selected (see accompanying sheet).
Exceeding the limit temperature generates an alarm.

Ambient conditions and temperature in the switch cabinet must be in accordance with the values indicated in the supplement.

Too little heat transfer at the heat exchanger in the external circuit (condenser).
The cooling unit may only be operated with cover, otherwise heat dissipation at the condenser is not sufficient, and the cooling unit may be damaged.

Immediately after the switch-on of the service voltage, the unit goes into the start-up/test mode. After that the evaporator fan continues to run. Compressor and condenser fans run on as required (the temperature of the switching threshold (T_set) has been reached, or are switched off (temperature lower than switching threshold (T_set )).

• Free discharge of any condensate produced must be provided to ensure trouble-free operation.

Indicator elements

The cooling unit has an operational display in the form of a LED on the external hood of the unit. If the light of this indicator remains on when the supply voltage is applied it shows that the unit is in the normal operating mode. If a fault occurs or if the unit is in the start-up or test mode, this indicator lights up in various flashing sequences which make it easier to diagnose fault in the unit (see Sections "Unit characteristics" and "What to do if")

Test mode / start-up

The test mode is basically activated after renewed connection of the supply voltage and is independent of the instantaneous ambient conditions when the door contact is closed.
First of all the unit runs through a start-up mode lasting 30 seconds which is followed by a test mode lasting 30 seconds.

Unit characteristics

Modus	Time curve	Characteristics
Start-up mode	t = 0s - < 30s t = 30s t = 32s	No function Internal fan start up External fan and compressor start up Flashing sequence of the status indicator: "off-dark-light-dark-off". Fault signal contact is closed.
Test mode	t >34s – 64s	Compressor and fans remains in operation during the period. Flashing sequence of the status indicator: "off-dark-light-dark-off". Fault signal contact is open. Should a fault arise during the test mode, the unit goes into the fault mode and the status indicator lights up according to the fault state (see chapter "Fault diagnosis")

The start-up mode is always additionally activated when the door limit switch is closed (see Sections "Door contact")

Door contact

To avoid an increased production of condensate and for safety reasons a door limit switch should be connected to the terminals provided (see circuit diagram (housing cover) or supplement) By the opening of the switch cabinet door and thus the opening of the switch all of the motors of the cooling unit are immediately switched off. After closing of the door the start-up mode (see Unit characteristics Sections) is run through which ensures a restart-up of the cooling unit with a time lag.

Centralised fault indication

The signalling of a fault in the cooling unit is effected by the breaking of a potential-free contact (see What to do if Sections). In this way a cable breakage in the fault signalling line is also signalled

Setting possibilities

By means of a DIP switch various switch cabinet temperatures as well as limit temperatures can be selected.
The location of the DIP switch on the control board is shown in the circuit diagram.
The coding options are represented on the circuit diagram. The circuit diagram is stuck to the inside of the device hood and is reproduced on the accompanying sheet.
Starting with a particular set-temperature in the switch cabinet, an upper limit temperature can be selected which, if exceeded, will generate an alarm. See accompanying sheet for factory settings.

Changes to the parameters of the unit set in the works may be made only by authorised persons! Isolate the cooling unit from the mains before changing the DIP-switsch settings. Otherwise the modified settings won't be accepted.

Cleaning and Maintenance

Hazard!
Isolate the cooling unit from the mains before carrying out any cleaning or maintenance operations.

Cleaning

The cleaning intervals depend upon the relevant operating conditions. In particular observe the following instructions.

• Clean the heat exchanger regularly.
• Clean the heat exchanger using a soft brush or pressurized air.
• We recommend that the condensate run-off opening be checked regularly.

Proceed as follows:

1. Disconnect the cooling unit from the power supply.
2. Remove external cover.
3. Clean heat exchangers.

Protect the electric components against leakage.

Damage to louvres
Do not use any pointed or sharp-edged objects. The ribs should not be compressed or damaged during the cleaning process.

Damage to electric connections on the covering hood
If the covering hood is removed, the electrical plug-in connections on the inside must be removed by hand. Do not forget to plug in when refitting!

Maintenance

The cooling circuit, as a maintenance-free, hermetically sealed closed system, is filled at the factory with the necessary coolant, checked for leakages and is subjected to a functional check run. The cooling unit is largely maintenance-free. The components around the external air circuit require maintenance and cleaning depending upon the ambient conditions (see Cleaning and Maintenance Section). After each service, the full performance capacity of the condensate run-off should be checked.

Stopping

If the cooling unit is not in use for a longer period, disconnect it. Ensure that unauthorised persons cannot start the cooling unit.
When the cooling unit is no longer needed, it must be disposed of by authorized specialist personnel in accordance with all applicable environmental protection regulations. (see also General Information Section)
It is essential that the refrigerant in the cooling system is properly removed by suction. Refrigerant emissions must be prevented.

What to do if...

... in spite of your care and attention a fault occurs? Check the following points first. If the fault is not then cleared, call an authorized specialist.

General errors

• No message via the service indicator

Fault	Possible cause(s)	Remedy
Unit fails to cool, fan in an internal airflow circuit is running	Temperature setting too high	Check temperature setting.
Unit fails to cool sufficiently.	Threshold values for usage exceeded. Lack of coolant Heat exchanger contaminated. Fan in internal airflow circuit faulty. Fan in external airflow circuit faulty. Air not circulating properly inside the switch cabinet	Check ambient temperature and internal load. Call authorized specialist, check unit for leaks Clean heat exchanger. Call authorized specialist, replace fan. Check assemblies and air circulation inside switch cabinet. Air intake and exhaust into/ from cooling unit into switch cabinet must be unimpeded. Check coding switch and cable connections.
Unit only cools irregularly	Coding switch incorrectly set or defective.	Set higher temperature at thermostat..
Condensate accumulates in switch cabinet	Blow-out temperature too low Switch cabinet not sufficiently sealed.	Close switch cabinet door. Remedy leakage at switch cabinet.
Condensate fails to drain	Condensate drainage clogged.	Clean condensate drainage. Condensate drainage hose must be inclined downward without showing a bend.

Fault diagnosis

• Message via the service indicator

If a fault occurs in the cooling unit, the status indicator goes over to flashing mode which in conjunction with the unit characteristics is to make initial fault diagnosis easier. Flashing sequences in the fault mode can be:

Status indicator, flashing sequence 1
(User error):

(5s, 1s, 1s, 1s) with periodic repetition

Status indicator, flashing sequence 2
(Unit fault):

(1s, 1s) with periodic repetition

Status indicator, flashing sequence 3
(Test/start-up mode):

(1s, 1s, 1s, 1s) with periodic repetition

Pfannenberg units with standard controller

The following table describes the technical cause as well as the fault remedy as a function of the unit characteristics.

Pos	Unit characteristics		Technical causes	Fault remedy
1	Compressor:	OFF	There is no supply of voltage to the unit.	Check back-up fuse and/or connect supply voltage
	Internal fan:	OFF
	External fan:	OFF
	Status LED:	OFF
	Fault signal contact:	open
2	Compressor:	ON	The test mode of the unit is active. This mode is left automatically at the latest after 60 s.	The unit switches to test mode once after each new connection to the power supply. No remedy of fault necessary.
	Internal fan:	ON
	External fan:	ON
	Status LED:	flashing (seq. 3)
	Fault signal contact:	open
3	Compressor:	OFF	The input for the door limit switch is open e.g. as a result of a switch cabinet door not closed or a bridge not set.	Insert link, close door contact switch or, with an engaged door contact switch, close the door
	Internal fan:	OFF
	External fan:	ON
	Status LED:	flashing (seq. 1)
	Fault signal contact:	closed
4	Compressor:	OFF	High pressure pressostat or motor protection switch has responded (overheating). Compressor switches on again automatically after the fault has been remedied (cooling) with a delay of 30 s.	Clean filter mat or heat exchanger in the external circulation. Possibly check the power dissipation in the switch cabinet to the installed cooling capacity of the air conditioner.
	Internal fan:	ON
	External fan:	OFF
	Status LED:	flashing (seq. 2)
	Fault signal contact:	open
5	Compressor:	OFF	Unit adjustment by means of the coding switch on the control electronics is not plausible. The unit setting must be changed.	Observe the operating instructions and note the coding key of the coding switch.
	Internal fan:	OFF
	External fan:	OFF
	Status LED:	flashing (seq. 1)
	Fault signal contact:	open
6	Compressor:	ON	The upper temperature limit (TL2) of the switch cabinet has been exceeded.	Clean filter mat or heat exchanger in the external circulation. Possibly check the power dissipation in the switch cabinet to the installed cooling capacity of the air conditioner.
	Internal fan:	ON
	External fan:	ON
	Status LED:	flashing (seq. 1)
	Fault signal contact:	open
7	Compressor:	ON	The temperature sensor TS1 is defective or has not been detected.	Replace temperature sensor TS1 or re- place the complete electronic control with a fixed-wired temperature sensor. Get in touch with the service department.
	Internal fan:	ON
	External fan:	ON
	Status LED:	flashing (seq. 2)
	Fault signal contact:	open
8	Compressor:	normal control	There is an air short circuit* in the switch panel, i.e. effective cooling of the switch panel is not possible. Air-conditioning is requested within short cycle times.	Relocate the power components in the switch cabinet or relocate the cooling unit. Select a top-mounting cooling unit or a side-mounting cooling unit as an alternative depending on the space situation.
	Internal fan:	ON
	External fan:	normal control
	Status LED:	flashing (seq. 1)
	Fault signal contact:	open

* Air short-circuit: An air short-circuit develops, if cool air at the air outlet of the cooling unit is led by means of power components built directly in front of it in an unfavourable way, not into the switch cabinet, but directly to the air inlet of the cooling unit. The consequence is overheating of the power components due to the lack of cooling.

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