AIR COOLING UNIT FOR INK JET PRINTING ON CERAMIC TILES. Mistral Basic USE AND MAINTENANCE MANUAL

Transcription

1 AIR COOLING UNIT FOR INK JET PRINTING ON CERAMIC TILES Mistral Basic USE AND MAINTENANCE MANUAL TRANSLATION OF THE MISTRAL INSTRUCTIONS LM 140 BASIC IN THE COOLING OFFICIAL UNIT LANGUAGE "ITALIAN" 1

2 TABLE OF CONTENTS 0 USING THE MANUAL 0.1 READING AND USING THE MANUAL EXPLANATION OF SYMBOLS GENERAL INFORMATION 1.1 TECHNICAL SUPPORT LIABILITY EXEMPTION PERSONNEL IN CHARGE WORKSTATION GENERAL CHARACTERISTICS 2.1 INTENDED USE PROHIBITED USES COMPONENTS TECHNICAL DATA OVERALL DIMENSIONS SAFETY RULES 3.1 GENERAL RULES AIRBORNE NOISE VIBRATIONS INSTALLED GUARDS SAFETY DEVICES INSTALLED RESIDUAL RISKS PICTOGRAM POSITIONING PERSONAL PROTECTIVE EQUIPMENT TRANSPORT AND HANDLING 4.1 GENERAL WARNINGS PACKAGING AND UNPACKING STORAGE CONDITIONS LIFTING AND TRANSPORT INSTALLATION 5.1 GENERAL WARNINGS AMBIENT CONDITIONS FOR USE AT THE USER'S CARE ROOM REQUIRED FOR USE AND MAINTENANCE POSITIONING CONNECTIONS MISTRAL LM 140 BASIC COOLING UNIT

3 TABLE OF CONTENTS 6 COMMISSIONING 6.1 GENERAL WARNINGS PRELIMINARY CHECKS OPERATION CONTROL PANEL STARTING MODES STOPPING MODES RESTARTING AFTER A STOP EMERGENCY STOP RESTARTING AFTER AN EMERGENCY STOP ADJUSTMENTS MAINTENANCE 7.1 GENERAL WARNINGS PREPARING FOR MAINTENANCE WORK CLEANING ROUTINE MAINTENANCE EXTRA-DUTY MAINTENANCE LUBRICATION CHARTS TROUBLESHOOTING RECOMMENDED SPARE PARTS DECOMMISSIONING 8.1 DISMANTLING AND SCRAPPING ATTACHMENTS NOTES WIRING DIAGRAM MISTRAL LM 140 BASIC COOLING UNIT 5

4 USING THE MANUAL READING AND USING THE MANUAL ATTENTION READ THE INSTRUCTIONS GIVEN IN THIS MANUAL WITH CARE TO ENSURE THAT THE MACHINE IS USED IN ACCORDANCE WITH THE SAFETY RULES AT ALL TIMES. The aim of this manual is to provide the operator with a complete technical guide covering all the procedures which must be strictly followed for good operation of the machine and the precautions required for personal safety. This manual is to be considered an integral part of the machine. It must be kept with care for the entire lifetime of the machine without making any changes which are not authorised by the manufacturer. If your copy of the manual becomes unreadable, ask the manufacturer for a new copy at the following address, specifying the information that can be found on the machine's nameplate, i.e.: - machine type - serial number Correctly interpreting and observing the rules and recommendations given in this manual ensures easy and safe use of the machine. This manual reflects the state-of-the-art the moment the machine was supplied and cannot be considered inadequate if there have been subsequent modifications according to further experience. The manufacturer reserves the right to update its products and manuals without being obliged to inform the users of machinery previously supplied of these modifications. The provision of information concerning updates of the machine and manual is to be considered as a form of courtesy. Hereinafter, the "mistral lm 140 BASIC" will be called "MACHINE" or "cooling machine". 6 MISTRAL LM 140 BASIC COOLING UNIT

5 0 USING THE MANUAL 0.2 EXPLANATION OF SYMBOLS THESE SYMBOLS ARE USED TO DRAW ATTENTION TO HAZARDS AND CRITICAL OPERATIONS FOR THE PERSONAL SAFETY OF THE OPERATOR THEY ARE IMPORTANT FOR YOUR SAFETY!! FAILURE TO OBSERVE THESE INSTRUCTIONS CAN LEAD TO SERIOUS INJURIES ATTENTION THIS SYMBOL IS USED TO DRAW ATTENTION TO WARNINGS CONCERNING OPERATION OR TO HAZARDOUS SITUATIONS OF THE MACHINE MISTRAL LM 140 BASIC COOLING UNIT 7

6 GENERAL INFORMATION TECHNICAL SUPPORT For the purpose of obtaining the best possible performance, users are advised to strictly follow the instructions provided in this manual. Should you require the assistance of our Technical Service Department, despite the rules having been scrupulously observed, it is essential for you to provide sufficient technical information to determine the possible nature of the fault and/or locate the parts of the machine functioning anomalously. If necessary, you can contact the following technical service departments: V.le Regina Pacis, Sassuolo (MO) - ITALY Tel Fax info@.it 8 MISTRAL LM 140 BASIC COOLING UNIT

7 1 GENERAL INFORMATION 1.2 LIABILITY EXEMPTION The Manufacturer shall not be held liable in the following cases: - use of non-original spare parts (in particular safety devices); - exceptional environmental events; - improper use of the machine; - use of the machine by unauthorised and/or untrained personnel; - insufficient maintenance; - total or partial failure to comply with instructions given in the manual and diagrams; - incorrect supply. Furthermore, the CE declaration of conformity envisaged by 2006/42/CE Machine Directive shall be invalidated in the following cases: - modifications or work on the machine that have not been authorised by the manufacturer, that alter the function of the machine and that may modify or generate new unexpected risks. MISTRAL LM 140 BASIC COOLING UNIT 9

8 GENERAL INFORMATION PERSONNEL IN CHARGE The machine must be run by persons that have been trained concerning the characteristics of the same and that are familiar with the contents of this manual. Operators must be aware of the contents of this manual and of all safety rules. They must also possess, or acquire by means of training, the following requirements: - general and technical preparation to understand the contents of this manual and correctly interpret the drawings and diagrams; - knowledge of the main hygienic, accident-prevention and technological standards; - general knowledge of the line where the machine is installed, of the auxiliary circuits and of the position of the energy isolating devices; - specific experience concerning the technology employed; - knowledge of how to proceed in emergency situations, of the position of personal protective equipment and of how to use it; - sufficient training to perform duties skilfully, especially in emergency situations. As well as the above requirements, maintenance technicians must possess basic technical knowledge as requested by their duties. 10 MISTRAL LM 140 BASIC COOLING UNIT

9 1 GENERAL INFORMATION 1.4 WORKSTATION Being the machine basically automatic, the constant presence of an operator is not necessary. The operator's duties are: - checking that the machine is operating correctly; - running the machine in manual mode with the controls on the electrical control panel. CONTROL AREA. This is the area in which the control panel is installed, namely the area in which the operator gives manual commands, and the rear side of the machine from which manual adjustments can be performed. AREA WHERE OPERATORS MAY STAND Fig MISTRAL LM 140 BASIC COOLING UNIT 11

10 GENERAL CHARACTERISTICS INTENDED USE The "MISTRAL LM 140 BASIC" is an automatic machine that has been designed and built for cooling the top face of ceramic tiles by means of blowing bars that create blasts of compressed air at a low temperature upstream to the ink jet printer. The blowing bars may have different widths. They are positioned along the transport line, near the digital printing machine so as to reduce the temperature of the top tile face to acceptable levels for good printing results. Operation of the blowing bars is controlled by a proximity sensor. Being a machine designed for professional uses, it must be run by appropriately trained personnel, which have been informed of the operating modes and safety precautions. The machine has been designed for industrial uses in the normal environments described in 5.2 and must be installed in a covered environment protected against adverse weather conditions. The definition of limits for the presence of personnel is the duty of the person in charge of designing the workstation(s) and may call for more restrictive measures. Energy supplies are at the user's care and must fulfil the requirements of 2.4 "TECHNICAL DATA". The machine is supplied with a switchboard and electrical equipment on board. ANY USE OTHER THAN THE ONE PROVIDED FOR IN THIS MANUAL IS STRICTLY TO BE AVOIDED AS THE DANGERS ASSOCIATED WITH SUCH USE ARE UNKNOWN! 12 MISTRAL LM 140 BASIC COOLING UNIT

11 2 GENERAL CHARACTERISTICS 2.2 PROHIBITED USE It is also forbidden to: - use the machine without its guards or with its guards open or with its safety devices deactivated, outof-order or missing; - tamper with or alter the guards and safety devices; - perform any operation on the machine unless all personal protective equipment is worn; - work on moving parts; - climb onto the machine; - clean or perform maintenance work on the machine while it is running or live; - use non-original spare parts or parts that differ from those removed; - perform any modification to the machine without the prior permission of the manufacturer; - drill holes in the cable raceways or electrical cable passage points; - drill holes in the compressed air pipeline; - drill holes in the cooling pipes; - use pressurised water to clean the switchboard; - direct the blast of compressed air or the drainage of condensate towards persons. THE MACHINE HAS NOT BEEN DESIGNED TO OPERATE IN AN EXPLOSIVE ENVIRONMENT. Any deviation from the above mentioned specifications calls for a specific written authorisation by the manufacturer. MISTRAL LM 140 BASIC COOLING UNIT 13

12 GENERAL CHARACTERISTICS COMPONENTS 1) Control panel 2) Blowing bar 3) Power switch 4) Temperature indicator for outgoing air 5) Power switch 6) Compressed air inlet on/off valve 7) Deoiling filter 8) Automatic condensate drainage unit of induction type 9) Pressure reducer 10) Compressed air outlet on/off valve 11) Pressure gauge measuring operating pressure at outlet 12) Transformer 13) Condenser (air cooling) 14) Dehydrating filter 15) Heat exchanger 16) Condensate drainage system 17) Refrigerating compressor Fig MISTRAL LM 140 BASIC COOLING UNIT

13 2 GENERAL CHARACTERISTICS Fig MISTRAL LM 140 BASIC COOLING UNIT 15

14 GENERAL CHARACTERISTICS TECHNICAL DATA Model LM 140 BASIC Air flow rate (l/min.) Max. incoming air pressure (bar) 14 Recommended operating pressure (bar) 3 Temperature of outgoing air ( C) * Min. ambient temperature ( C) + 1 Max. ambient temperature ( C) + 45 Installed power (kw) 1.5 Single-phase voltage (V - Hz) Weight of machine empty (kg) 122 Coolant R404A * With an ambient temperature of 35 C. 16 MISTRAL LM 140 BASIC COOLING UNIT

15 2 GENERAL CHARACTERISTICS 2.5 OVERALL DIMENSIONS A B C D Fig Model LM140 BASIC A (mm) 580 B (mm) 655 C (mm) 1240 D (mm) 400 / 500 / 600 / 700 / 800 / 900 / 1000 / 1100 MISTRAL LM 140 BASIC COOLING UNIT 17

16 SAFETY RULES GENERAL RULES Read this manual carefully before starting, operating or performing maintenance on the machine and make entirely sure that any hazard condition has been eliminated. Do not wear rings, wristwatches, jewellery, loose or hanging garments such as ties, torn clothes, scarves, unbuttoned or unzipped jackets, which are liable to get caught in moving parts of the machines. Long hair must be tied back. When there is a risk of being hit by projected or falling parts, both solid or in other form, use goggles with side shields, as well as hard hats and gloves if necessary. Connection work, starting, maintenance, measurements or adjustments of the electrical equipment and components must be entrusted to qualified electricians. Access to the switchboard must be restricted to qualified personnel that has been instructed concerning the hazards relating to electrical components and on how to behave in the event of dangerous situations (see 1.3). Check before the beginning of every cycle that all of the guards are in their places and that all of the safety devices are present and efficient and have not been tampered with. 18 MISTRAL LM 140 BASIC COOLING UNIT

17 3 SAFETY RULES 3.2 NOISE EMISSION The machine has been designed and built so as to limit exposure of staff to noise to a minimum. In full load conditions, the noise measurements taken in compliance with ISO standards are: - continuous equivalent sound pressure level (Leq) lower than 72 db(a); - peak level (Leq) < 130 db(c). ATTENTION THE USER MUST PERFORM REGULAR MEASUREMENTS OF THE NOISE LEVEL IN THE WORKING ENVIRONMENT OWING TO THE PRESENCE AND SIMULTANEOUS USE OF DIFFERENT MACHINES. 3.3 VIBRATIONS The machine does not transmit vibrations that are harmful for operators, for operation and for machines placed in the immediate vicinity. MISTRAL LM 140 BASIC COOLING UNIT 19

18 SAFETY RULES INSTALLED GUARDS 1) Fixed side guards made of bent plate panels, 4 guards These prevent access inside the machine. 2) Fixed upper guard made of bent plate panels. This prevents access to the machine from the top side. 3) Fixed electro-welded net guard on the condenser fan. This prevents access to the blowing fan Fig NEVER REMOVE THE GUARDS WHILE THE MACHINE IS RUNNING. NEVER START THE MACHINE UNLESS ALL GUARDS ARE IN PLACE. CHECK DAILY, BEFORE RUNNING THE MACHINE, THAT THE GUARDS ARE CORRECTLY POSITIONED. 20 MISTRAL LM 140 BASIC COOLING UNIT

19 3 SAFETY RULES 3.5 SAFETY DEVICES INSTALLED 1) Power switch Installed on the cooling machine. When it is turned to "0", all energy supplies to the machine are interrupted immediately. 2) Power switch On the control panel. When it is turned to "0", all energy supplies to the machine are interrupted immediately. 1 2 Fig CHECK DAILY AND BEFORE STARTING THE MACHINE THAT THE SAFETY DEVICES ARE CORRECTLY POSITIONED AND IN WORKING ORDER. MISTRAL LM 140 BASIC COOLING UNIT 21

20 SAFETY RULES RESIDUAL RISKS A residual risk is a potential risk that has been partially eliminated by the manufacturer and that can cause injuries to the operator if the latter adopts incorrect or improperly interpreted working methods or practices. 1 - Danger of moving parts. Risk of contact with the fan wheel of the electric condenser fan. This danger exists only in the event that maintenance work is performed on the fan wheel with the electricity supply connected and after removing the guard. The residual risk is avoided by instructing the maintenance person concerning the correct practices to adopt when working inside the machine. 2 - Danger: Live components Risk of contact with live components inside the control panel. This danger exists only in the event of work performed inside the panel when this is live. The residual risk is avoided by instructing the maintenance person concerning the correct practices to adopt when working on the panel. 3 - Danger of eye injuries Risk of contact with particles of dust formed by the movement of large amounts of air coming from the blowing pipes. This danger exists only in the event that staff members are too close to the blasts of air coming from the pipes. The residual risk is avoided by instructing the maintenance person concerning the correct practices to adopt when working on the machine Fig MISTRAL LM 140 BASIC COOLING UNIT

21 3 SAFETY RULES 3.7 PICTOGRAM POSITIONING The machine features a series of pictograms that mark out dangerous points or provide safety instructions that all operators must observe to ensure a fully safe use of the machine. 1) Danger. 2) Danger of high voltage. 3) Read this manual before performing any work on the machine. Fig CHECK REGULARLY THAT THE PICTOGRAMS ARE LEGIBLE AND IN GOOD REPAIR AND REPLACE THEM IF THEY ARE NOT. MISTRAL LM 140 BASIC COOLING UNIT 23

22 SAFETY RULES PERSONAL PROTECTIVE EQUIPMENT The operators that run and maintain the machine must be wearing personal protective equipment, as established by the current regulations in the user's country. Making reference to the contents of 3.6 "Residual risks", the use of the following equipment is necessary when running or performing maintenance on the machine: - Gloves: complying with the UNI-EN 388 standard: Mechanical risks. To be worn when: - performing maintenance, cleaning and removal of by-products. - Goggles: complying with the EN-166 standard: Risk of projection of particles of dust due to the movement of air generated by the blasts coming from the pipes. To be worn: - in the event of close visual checks performed with the machine running, - when cleaning with low pressure air. 24 MISTRAL LM 140 BASIC COOLING UNIT

23 TRANSPORT AND HANDLING GENERAL WARNINGS When transporting the machine with a forklift truck, pay attention to the load and proceed with caution. Avoid driving over uneven surfaces or braking abruptly. When moving the machine, keep it as low as possible to ensure the maximum stability and to afford maximum visibility for the operator. The entire area is subject to the risk of falling loads and must be kept under constant control, also during installation and handling with lifting gear. The staff in charge of lifting and transporting the machine must be SUITABLY TRAINED. All operations MUST BE performed with the utmost care in order to prevent damage or accidents. 4.2 PACKING AND UNPACKING The machine is secured to a pallet by means of binds and shrink-wrapped. C A = 1200 mm B = 1000 mm C = 1200 mm A B Fig IN THE EVENT OF STORAGE OF SEVERAL MACHINES, IN ORDER TO PREVENT IRREPARABLE DAMAGE, IT IS STRICTLY PROHIBITED TO STACK THE RELATIVE PACKAGES. IN THE EVENT OF DISPOSAL OF PACKAGING MATERIALS, RESPECT THE SPECIFIC RULES IN FORCE IN THE COUNTRY WHERE THE MACHINE IS INSTALLED. 26 MISTRAL LM 140 BASIC COOLING UNIT

24 4 TRANSPORT AND HANDLING 4.3 STORAGE CONDITIONS Should the purchaser intend to store the machine at its premises, the machine must be kept in a covered environment, sheltered from adverse weather conditions, at a minimum temperature of -10 C, with an average temperature over 24 hours that must not exceed +35 C, with a humidity level of 95% at the most (without condensation). The machine should be kept in the position in which it was transported, without stacking material on top of it, to avoid damaging its functional parts and compromising its operation and safety. 4.4 LIFTING AND TRANSPORT To lift and move the packed machine, use a fork lift truck with adequate capacity for the load (see technical data). Place the forks under the pallet, in the indicated positions (highlighted by adhesive labels). Weight = 170 kg Forks Fig THE LIFTING GEAR EMPLOYED MUST HAVE A LOAD LIFTING CAPACITY THAT EXCEEDS THE WEIGHT TO LIFT AND MUST GUARANTEE STABILITY DURING TRANSPORT OF THE LOAD. MISTRAL LM 140 BASIC COOLING UNIT 27

25 INSTALLATION GENERAL WARNINGS READ THE INSTRUCTIONS GIVEN IN THIS MANUAL CAREFULLY BEFORE INSTALLING THE MACHINE TO ENSURE THAT IT IS USED IN ACCORDANCE WITH THE SAFETY RULES AT ALL TIMES. It is imperative that work on the machine is performed by qualified and authorised persons. These staff members must also be authorised and fully informed about operation and safety of the machine. Make sure the power supply line fulfils the voltage and frequency requirements printed on the machine's nameplate. 5.2 AMBIENT CONDITIONS FOR USE Make sure that the floor where the machine is to be installed is free of bumps or uneven areas which could affect alignment and place operation in jeopardy. To ensure correct operation of all parts, the machine must be used in a covered industrial environment granting good visibility and installed in an area with a low dust level to prevent contamination of the surrounding environment due to operation of the electric fans. Provide an area with an exchange of air that is sufficient to prevent excessive overheating of the environment, which would reduce the efficiency of the cooling unit. - relative humidity of 95% at the most The machine's operation area and the gangways must be provided with adequate lighting for reading the signs on the machine and for the machine to be used perfectly by the operator during both normal operation and routine maintenance. The lighting must not be concentrated at a single point to avoid dazzling the operator. The recommended lighting requested for operation is approx. 300 Lux, at a height of 1 metre from the floor. Unless otherwise indicated, the floor must: - withstand a specific load of 2 kg/cm 2 28 MISTRAL LM 140 BASIC COOLING UNIT

26 5 INSTALLATION 5.3 AT THE USER'S CARE The user must provide: - installation areas complying with the local standards in force concerning health and safety at work; - an electricity supply that complies with the regulations in force in the place of installation; - a compressed air supply that complies with the regulations in force in the place of installation; - an efficient earth connection system; - a circuit breaker with automatic protection against short circuits, earth discharges and leakage between the electrical supply line and the machine. 5.4 ROOM REQUIRED FOR USE AND MAINTENANCE For lifting and transport: A sufficient clearance must be left around the machine to enable access by suitable lifting gear. For maintenance: A sufficient clearance must be left around the machine in order to make normal operation, adjustment and maintenance as simple and comfortable as possible. There must also be adequate space to gain access to the machine with lifting equipment, which might be required for maintenance purposes (fig.5.4.1). A clearance of 1000 mm at least on the sides of the machine must be guaranteed to provide an area for movement and escape in emergency situations Fig MISTRAL LM 140 BASIC COOLING UNIT 29

27 INSTALLATION POSITIONING Position the blowing bars and proximity/temperature sensors as indicated in fig FTC1 B B B A A (mm) = B (mm) = 150 C (mm) = D (mm) = C D Fig FTC1 Photocell detecting incoming material 30 MISTRAL LM 140 BASIC COOLING UNIT

28 5 INSTALLATION Control panel Cooling unit Blowing bars Inlet Outlet Condensate drainage Fig FOR EXCELLENT PERFORMANCE OF THE COOLING SYSTEM, INSTALL THE CONTROL PANEL AND COOLING UNIT INSIDE THE CONDITIONED CABIN OF THE INK JET PRINTER. MISTRAL LM 140 BASIC COOLING UNIT 31

29 INSTALLATION CONNECTIONS Electrical connections The machine is supplied with a control panel and a power supply cable. As far as installation in Italy is concerned, the power supply line must feature a differential switch. The differential switch must have an intervention threshold (sensitivity) of at least 300 ma. Make sure the voltage and frequency of the power supply line fulfil the requirements of the machine, which are indicated on the machine's nameplate or on the wiring diagram. Connect the control panel to a distribution board featuring fuses that protect the machine in the event of short circuits or insulation failures. The switchboard has been developed to resist the short-circuiting current indicated in the wiring diagrams (not above 10 ka). The power supply line must limit current to lower values. MAKE SURE THE POWER SUPPLY VOLTAGE FULFILS THE RATINGS PROVIDED IN THE TECHNICAL DATA SECTION PROVIDE A GROUNDING LINE OF A SIZE AND TYPE COMPLYING WITH THE STANDARDS IN FORCE IN THE USER'S COUNTRY Condensate drainage connection Condensate is drained at the same pressure at which air is fed into the cooling unit. Secure the drainage line correctly. The cooling unit is fitted with an automatic condensate drainage unit with electronic level control. Secure the drainage unit to a drainage circuit or container. The drainage system cannot be connected to pressurised systems. Condensation collected in the cooling unit contains oily particles that are released into air by the compressor. Drain condensate in accordance to the local standards in force. CONDENSATE DRAI- NAGE PIPE RILSAN PIPE Ø 8 CONDENSATE DRAINAGE Fig MISTRAL LM 140 BASIC COOLING UNIT

30 5 INSTALLATION NEVER DISPOSE OF CONDENSATE IN THE ENVIRONMENT! IT IS RECOMMENDED TO CONVEY DRAINED CONDENSATE TO AN AIR/OIL SEPARATOR. Connection to the compressed air network The cooling unit must be connected to the general compressed air supply line by means of a 1" pipe to be connected to the inlet valve. Temperature and quantity of air entering the cooling unit must comply with the indications given in 2.4 "Technical Data". Connection pipes must have a suitable size to withstand the capacity of the cooling unit and must not feature rust, burrs or other impure matters. The cooling unit has been designed with special features to reduce any shaking that may occur during operation. It is recommended to use connection pipes that isolate the cooling unit from possible vibrations coming from the line (hoses, vibration-damping joints, etc.) COMPRESSED AIR INLET Fig MISTRAL LM 140 BASIC COOLING UNIT 33

31 COMMISSIONING GENERAL WARNINGS - Make sure that the safety labels (pictograms) on the machine are present and legible. - Make sure the guards on the machine are present and in working order. - Make sure that the safety devices installed on the machine are present and in working order. 6.2 PRELIMINARY CHECKS Preliminary checks must be performed by technicians of the manufacturer or staff authorised and trained by the latter, and are therefore not described in this manual. In order to enable the end user to select the staff members capable of supporting our technician, here below is a short account of the preliminary checking operations that must in no case be considered exhaustive. Should the user wish to perform these operations independently, it is essential to read this manual beforehand in order to acquire sufficient knowledge of the purpose and effect of the commands given. - Make sure that the material detecting photocell is working correctly. - Check for oil and/or coolant leaks from pipes. - Check if the position of the photocell is correct. - Check if the position of the blowing bars is correct. - Make sure the compressed air pipes and pipe fittings are firmly secured in place. - Make sure that all condensate drainage equipment is firmly fixed and connected to a container or collection system. - Make sure that the manual valve on the condensate drainage circuit is open. - Turn on the power supply switch. - Turn on the general isolating switch - pos. 1 - on the control panel. - Wait at least two hours before starting the dryer unit (the heating coil must heat oil in the compressor). - Make sure that the DMC14 electronic instrument is on. - Make sure that the power draw fulfils the power requirements indicated on the nameplate. - Make sure that the fan is running in the right direction, namely in the direction indicated by the adhesive arrow labels on the condenser (air cooling). - Wait a few minutes for the cooling unit to reach the right temperature. - Slowly open the air inlet valve. - Slowly open the air outlet valve. - Make sure that there are no air leaks from the pipeline. - Check operation of the condensate drainage system. Check the first operations. 34 MISTRAL LM 140 BASIC COOLING UNIT

32 6 COMMISSIONING 6.3 OPERATION Once it has been adjusted, the machine's operation is very simple and fully automatic. The operator is requested only to check operation periodically. The incoming tile engages photocell FTC1 that gives the 'material presence' signal to the control panel. This signal allows the solenoid valves, supplying compressed air to blowing bars, to open so that cool air, coming from the cooling unit may be blown over the top face of the tiles and temperature of the latter may be reduced. FTC1 Fig MISTRAL LM 140 BASIC COOLING UNIT 35

33 COMMISSIONING 6 Cooling unit flow chart Fig Heat exchanger b - Air-coolant heat exchanger c - Condensate separator 2 Refrigerating gas pressure switch 3 Safety thermostat TS 4 Refrigerating gas pressure switch PA 5 Refrigerating gas pressure switch (fan) 6 Refrigerating compressor 7 Hot gas by-pass valve 8 Condenser (air cooling) 9 Condenser fan 10 Dehydrating filter 11 Tube 12 Temperature probe T Temperature probe T2 (fan checking) 12.2 Temperature probe T2-T8 13 Condensation drainage system valve 17 Electronic control instrument 21 Bekomat discharge unit 25 Heating coil inside compressor casing 36 MISTRAL LM 140 BASIC COOLING UNIT

34 6 COMMISSIONING Operation of the cooling unit All cooling units described in this manual have the same operating principle. Hot and humid incoming air enters the air-air exchanger and is then conveyed to the evaporator (air-coolant exchanger). Here, air is cooled to a temperature of 2 C and any moisture is condensed. Condensate is collected in a separator and is therefore ejected by the condensate drainage unit. Cool and dry air therefore returns to the air-air exchanger to be heated again before exiting the cooling unit. Temperature of outgoing air is about 8 degrees lower than temperature of incoming air. Refrigerating circuit Refrigerating gas is pumped out by the compressor at a high pressure and therefore enters the condenser. Here, it is cooled down, condensation takes place and air is transformed into a liquid at high pressure. The liquid is forced through a tube. By means of the pressure drop, it reaches the requested temperature. The liquid coolant at low pressure enters the evaporator (air-coolant exchanger). Heat in the air is absorbed by the liquid that therefore evaporates, namely switches from liquid to gaseous state. The low pressure and low temperature gas is sent back to the compressor, where it is re-compressed and the cycle restarts from the beginning. When the heat load of the compressor has reduced, the excess coolant is automatically diverted to the compressor by means of the hot gas by-pass valve. Refrigerating compressor The refrigerating compressor is the system's pump where gas coming from the evaporator (low pressure side) is compressed to reach condensation pressure (high pressure side). The compressors employed, all of leading makes, are designed for application with high compression ratios and great changes in temperature. The fully air-tight construction guarantees perfect tightness of gas, a high energy efficiency and a long service life. The pumping unit, installed on shock-absorber springs, reduces noise and shaking to a minimum. The electric motor is cooled by the refrigerating gas that is drawn in and that passes through the windings before it enters the compression cylinders. An overload cutout protects the compressor against high temperature and high current. The cutout is automatically reset when normal temperature conditions are achieved. Condenser The condenser is the unit in which gas coming from the compressor is cooled and condensed and passes to liquid state. It is basically composed of a set of copper pipes (in which gas circulates) installed within a lamellar pack made of aluminium. Cooling takes place by means of a high efficiency axial fan that forces air inside the cooling unit and thus into the lamellar pack. Temperature of ambient air must not be higher than the ratings shown on the nameplate. ATTENTION It is essential to keep the cooling unit clean and to remove any build-ups of dust or impure particles. MISTRAL LM 140 BASIC COOLING UNIT 37

35 COMMISSIONING 6 Dehydrating filter Any traces of moist and debris that may build up in the refrigerator system or sludge that could form due to prolonged use of the cooling unit tends to limit lubrication of the compressor and clog the tubes. The dehydrating filter holds back all impure particles that circulate within the circuit. Tube This is section of copper pipe with a small diameter, which is fitted between the condenser and the evaporator to create a throttling section for the refrigerating liquid. This throttling section causes a drop in temperature, which depends on the temperature you wish to obtain in the evaporator. The lower the pressure at the exit of the tube, the lower the evaporation temperature. The diameter and the length of the tube are accurately designed to achieve the necessary performance. The tube calls for no maintenance or adjustment. Evaporator This is also called air-coolant exchanger. Liquid that has formed in the condenser evaporates in this section of the circuit. During evaporation, the refrigerating liquid tends to absorb the heat of compressed air on the other side of the exchanger. Condensate separator Cold air exiting the evaporator is conveyed inside a high efficiency condensate separator, composed of a stainless steel net. As soon as the particles of condensate come into contact with the metal net, they are separated and are ejected through the discharge device. Cold and dry air thus obtained is conveyed to the exit. This type of condensate separator offers the advantage of a high efficiency also when the air flow rate changes. Hot gas by-pass valve This valve injects some of the hot gas (taken from the compressor delivery point) into the pipe between the evaporator and the compressor suction point, whilst maintaining temperature/evaporating pressure at about +2 C. This injection prevents formation of ice inside the evaporator at any loading condition. Regulation The hot gas by-pass valve is regulated during final testing of the cooling unit. As a general rule, there is no need for regulation. In any case, if adjustments are necessary, they must be performed by an expert technician. Use of the Schraeder ¼ valve must be justified by actual malfunctioning of the refrigerating system. Every time a pressure gauge is connected to the valve, part of the coolant is discharged. Before the flow of compressed air crosses through the cooling unit, turn the adjuster screw (position A of figure) until you obtain the required setting: Hot gas settings (R134.a): temperature 0.5 C (+0.5 / -0 K) pressure 2.0 barg (+0.1 / -0 bar) Hot gas settings (R404A): temperature 0.5 C (+0.5 / -0 K) pressure 5.2 barg (+0.1 / -0 bar) 38 MISTRAL LM 140 BASIC COOLING UNIT

36 6 COMMISSIONING Refrigerating gas pressure switch PA-PB-PV To guarantee safe operation and proper working order of the cooling unit, the refrigerating gas circuit is fitted with a set of pressure switches. PB PA Low pressure switch installed on suction side (casing) of the compressor. It is activated if pressure drops below the threshold. Restarting is automatic when rated conditions are resumed. Calibration pressure: R 404 A Stopping 1.0 barg - Starting 5.0 barg High pressure switch installed on pressure side of compressor. It is activated if pressure rises above the threshold. Restarting is performed manually by pressing the button on the pressure switch. Calibration pressure: R 404 A Stopping 32 barg - Manual starting PV Fan pressure switch installed on the condenser outlet. It keeps temperature/ condensing pressure within the operating limits set (air cooling). Calibration pressure: R 134.a Starting 11 barg (47 C) - Stopping 8 barg (36 C) - Tolerance ± 1 bar R 404 A Starting 20 barg (45 C) - Stopping 16 barg (36 C) - Tolerance ± 1 bar Safety thermostat Ts To guarantee safe operation and proper working order of the cooling unit, the refrigerating gas circuit is fitted with a thermostat (TS). The thermostat's sensor, in the event of abnormal delivery temperatures, stops the refrigerating compressor before this goes subject to permanent damage. The thermostat is reset manually. This must be done after resuming normal working conditions. Unscrew the cap, pos. 1, and press reset button, pos. 2. TS settings: temperature 100 C (+2 / -2 K) Compressor heating coil At a low temperature, oil tends to mix with refrigerating gas. This means that when the compressor starts, you may notice "liquid throbbing" and oil moving within the refrigerating circuit. To minimise this problem, a heating coil has been installed inside the compressor's casing. When the switchboard is on but the compressor is halted, this keeps oil at a suitable temperature. The heating coil is equipped with a thermostat that prevents oil overheating. ATTENTION The heating coil must be turned on at least two hours before the compressor is started. MISTRAL LM 140 BASIC COOLING UNIT 39

37 COMMISSIONING CONTROL PANEL 2 1 Fig ) POWER SWITCH. This connects the machine to or isolates it from the electricity supply line. 2) Button for turning on machine. This starts the machine functions. 40 MISTRAL LM 140 BASIC COOLING UNIT

38 6 COMMISSIONING 3 4 Fig ) POWER SWITCH. This connects the cooling unit to or isolates it from the electricity supply line. 4) DISPLAY. This displays the temperature of outgoing air. Button to gain access to programming Button to quit programming / reduce a setting Button to increase a setting LED for displaying cooling unit alarm status LED for displaying the set temperature scale, C LED for displaying the set temperature scale, F Available LED MISTRAL LM 140 BASIC COOLING UNIT 41

39 COMMISSIONING 6 By means of the digital thermometer with alphanumeric display, the DMC14 electronic instrument displays the Dew Point recorded by the probe installed inside the evaporator. The LED comes on to signal any of the following alarm conditions: - Dew Point is too high; - Dew Point is too low; - probe is faulty. If the probe is faulty, the instrument displays the message "PF" (Probe Failure). The alarm is activated immediately after. In the event of an alarm due to a low Dew Point (ASL fixed parameter equal to 28.5 F or -2 C), the warning message is delayed for a fixed time (AdL parameter) equal to 30 sec, whereas in alarm condition for a Dew Point that is too high, the threshold setting (ASH parameter) can be set by the user and delayed for a set time, AdH, that can also be programmed (the instrument has some factory settings that are given below). As soon as the Dew Point falls within the permissible temperature range, the alarm is deactivated. The DMC14 allows for remote signalling of alarm conditions by means of a clean (volt free) contact on terminals 8 and 9. See also wiring diagrams attached (max 250V 1A, min 5VDC 10mA): - with cooling unit off or in alarm condition, contact is open - with cooling unit on and smooth operation, contact is closed Operation Upon turning on the instrument, the current Dew Point is displayed: the display shows the temperature measured in degrees Celsius with a 0.5 C resolution or in degrees Fahrenheit with a 1 F resolution. Setting up Hold down keys and for at least 5 seconds to gain access to programming. The first of the parameters that can be set up appears (Ton). Press key to display the relative setting. To select a parameter, press To change the parameter you have selected, press and All parameters can be modified, as illustrated in the chart here below: You can quit programming at any moment, by pressing keys and If you do not perform any operations for 30 seconds, the programming session is automatically interrupted. 42 MISTRAL LM 140 BASIC COOLING UNIT

40 6 COMMISSIONING 6.5 STARTING MODES To start the machine, preferably perform the following sequence of operations: 1) Turn the POWER SWITCH on the cooling unit "ON" (pos.1 fig.6.5.1). 2) Turn the POWER SWITCH on the cooling unit "ON" (pos.2 fig.6.5.1). 3) Slowly open the air inlet valve. 4) Slowly open the air outlet valve. 2 1 Fig MISTRAL LM 140 BASIC COOLING UNIT 43

41 COMMISSIONING STOPPING MODES 1) Turn the POWER SWITCH of the cooling unit "OFF" (pos.1 fig.6.5.1). 2) Turn the POWER SWITCH of the cooling unit "OFF" (pos.2 fig ). 3) Slowly close the air inlet valve. 4) Slowly close the air outlet valve. 6.7 RESTARTING AFTER A STOP To restart the machine after a stop, perform the following sequence of operations: 1) Turn the POWER SWITCH on the cooling unit "ON" (pos.1 fig.6.5.1). 2) Turn the POWER SWITCH on the cooling unit "ON" (pos.2 fig.6.5.1). 3) Slowly open the air inlet valve. 4) Slowly open the air outlet valve. 6.8 EMERGENCY STOP To stop the machine in emergency situations, use: 1) POWER SWITCH. On the control panel. This turns on the power supply to the control panel. 2) POWER SWITCH. This is located on the cooling unit. This provides electrical power to the cooling unit. 6.9 RESTARTING AFTER AN EMERGENCY STOP To restart the machine after an emergency stop, perform the following sequence of operations: 1) Turn the POWER SWITCH on the cooling unit "ON" (pos.1 fig.6.5.1). 2) Turn the POWER SWITCH on the cooling unit "ON" (pos.2 fig.6.5.1). 44 MISTRAL LM 140 BASIC COOLING UNIT

42 6 COMMISSIONING 6.10 ADJUSTMENTS After starting the machine, no particular adjustments should be made. Operation is controlled automatically based on the settings that the operator has entered in the control panel. MISTRAL LM 140 BASIC COOLING UNIT 45

43 MAINTENANCE GENERAL WARNINGS Never clean, lubricate or service the machine while it is connected to the power supply. THE POWER SWITCH MUST BE TURNED OFF ('0') AND PADLOCKED IN THIS POSITION. The manufacturer accepts no responsibility for damage or accidents arising out of failure to observe the rules provided in this manual. The maintenance procedures are extremely simple and are essential to ensure correct operation and a long service life. The stated checking and maintenance work frequencies are purely guidelines and are to be considered as minimum maintenance requirements. If it is necessary to deactivate safety devices, maintenance must be entrusted to authorised maintenance staff, which must pay the utmost attention and don all the envisaged personal protective equipment. Safety devices may be deactivated only for the time strictly necessary for the maintenance work to be completed. At the end of work, all safety devices must be put back into working order. After cleaning and servicing the machine, make sure all guards are refitted and that the machine is put in working condition. 7.2 PREPARING FOR MAINTENANCE WORK Before performing any cleaning and/or maintenance, either external or internal, make sure that there are no hazardous conditions exposing operators to risks. Isolate the machine from the energy supplies in accordance to the following procedure: 1) Stop the machine cycle. 2) Turn the power switch "off". 3) Close the air inlet and outlet ball valves. 4) Depressurise the entire system. BEFORE PERFORMING ANY MAINTENANCE ON THE COOLING UNIT, WAIT AT LEAST 30 MINUTES. 46 MISTRAL LM 140 BASIC COOLING UNIT

44 7 MAINTENANCE 7.3 CLEANING Never use solvents or other flammable liquids to clean the machine. Instead use authorised nonflammable and non-toxic commercial solvents. Do not use compressed air to clean the machine. If it is really not possible to use any other system, wear safety goggles and keep air pressure at a low value. Never use blasts of pressurised water to clean the machine AND CONTROL panel. Daily cleaning: - Make sure the work area if clean. - Keep the adhesive safety labels clean so that they are perfectly visible at all times. - Clean the floor and machine base to remove any oil stains. When cleaning safety devices and guards, pay attention in order not to modify their position. 7.4 ROUTINE MAINTENANCE Daily maintenance - Make sure the pictograms are correctly positioned and perfectly readable ( 3.7). - Make sure all guards are present and correctly positioned ( 3.4). - Check correct operation and efficiency of all safety devices ( 3.5). - Check tightness of all pneumatic circuit fittings. - Check operation of the condensate drainage system. - Make sure the dew point temperature is correctly set up (see 2.4 "Technical Data"). - Make sure the condenser is clean. Monthly maintenance - Clean the condenser with a jet of compressed air directed from the inside towards the outside. Repeat the operation in the opposite direction. Pay attention not to bend the aluminium fins. ATTENTION THE DIRECTION OF THE JET OF AIR MUST ALWAYS BE PARALLEL TO THE FINS AND AT A LOW PRESSURE (MAX. 2 BAR) TO PREVENT DAMAGE MISTRAL LM 140 BASIC COOLING UNIT 47

45 MAINTENANCE 7 Every six months - Check the continuity of the machine's PE circuit, as envisaged by the EN standard. This check must be made after every operation involving the machine's PE circuit. - Check the state of the contacts of electrical contactors. If these are considerably oxidised or are functioning improperly, replace the contactors. - Check the condition of the electrical equipment and assess its operating reliability during the lapse of time running between this check and the next. Yearly maintenance - Check the refrigerating circuit for oil and coolant leaks. - Measure and record the power draw. Make sure that the values read are accepted, as indicated in the specifications table. - Check the condensate drainage hoses and replace them if necessary. - After completing your work, check operation of the machine. 7.5 EXTRA-DUTY MAINTENANCE Extra-duty maintenance calls for a specific knowledge of the machine. These operations must be performed by qualified technicians in maximum safety condition with the machine halted and isolated from the electrical and oil supplies, or by qualified technicians of the user following the instructions and with the written authorisation of 7.6 LUBRICATION CHARTS The machine does not feature points requiring lubrication 48 MISTRAL LM 140 BASIC COOLING UNIT

46 7 MAINTENANCE 7.7 TROUBLESHOOTING Problems can be of a mechanical, electric and/or electronic nature, or a combination of these. Therefore exhaustive knowledge of these parts can be particularly useful for the operator/maintenance person. If the problem remains, contact PROBLEM The machine does not start. The compressor does not work. POSSIBLE CAUSE - SOLUTION Make sure that the unit is powered. Check wiring. An overload cutout has tripped - wait 30 minutes and make a new attempt. Check wiring. If installed - Reset the overload cutout and/or the starting relay and/or the starting condenser and/or the operating condenser. If installed - The PA high pressure switch has cut in - see relative paragraph. If installed - The PB low pressure switch has cut in - see relative paragraph. If installed - The TS safety thermostat has cut in - see relative paragraph. If the fault remains, replace the compressor. The condenser fan does not work. Check wiring. The PV pressure switch is faulty - contact a qualified technician. Refrigerating gas is leaking - contact a qualified technician. If the fault remains, replace the fan. The dew point is too high. The cooling unit does not start - see relative paragraph. La T1 probe (Dew Point) is not recording temperature correctly - push the probe until it reaches the bottom of the measuring sump. The refrigerating compressor does not work - see relative paragraph. Ambient temperature is too high or ventilation is not sufficient - provide sufficient ventilation (air cooling). Incoming air is too hot - make sure it fulfils the ratings shown on the nameplate. Pressure of incoming air is too low - make sure it fulfils the ratings shown on the nameplate. The amount of air is greater than the cooling unit's capacity - reduce the flow rate - make sure it fulfils the ratings shown on the nameplate. The condenser is dirty - clean it. The fan does not work - see relative paragraph. The cooling unit does not drain condensate - see relative paragraph. The hot gas by-pass valve needs to be re-calibrated - contact a qualified technician for the calibration operations. Refrigerating gas is leaking - contact a qualified technician. MISTRAL LM 140 BASIC COOLING UNIT 49

47 MAINTENANCE 7 PROBLEM The dew point is too low. POSSIBLE CAUSE - SOLUTION The fan is always on - THe PV pressure switch is faulty - Replace it. Ambient temperature is too low - resume correct working conditions. The hot gas by-pass valve needs to be re-calibrated - contact a qualified technician for the calibration operations. The pressure drop in the cooling unit is too great. The cooling unit does not drain condensate - see relative paragraph. The dew point is too low - condensate has frozen and air cannot pass - see relative paragraph. Connection hoses are throttled - Check. The cooling unit is not draining condensate continuously. The cooling unit is draining condensate continuously. There is water in the line. Condensate drainage valve is closed - Open it. Check wiring. The dew point is too low - condensate has frozen - see relative paragraph. The drainage unit is not working properly. The drainage unit is dirty. The cooling unit does not start - see relative paragraph. If installed - the by-pass lets untreated air pass - Close it. The cooling unit does not drain condensate - see relative paragraph. The dew point is too high - see relative paragraph. If installed - The PA high pressure switch has cut in. Locate which of the following situations caused the device to cut in: Ambient temperature is too high or ventilation is not sufficient - provide sufficient ventilation (air cooling). The condenser is dirty - Clean it (air cooling). The fan does not work - see relative paragraph. Restart the pressure switch by pressing the button on the switch - check operation of the cooling unit. The PA pressure switch is faulty - contact a qualified technician. If installed - The PB low pressure switch has cut in. If installed - The TS safety thermostat has cut in. Refrigerating gas is leaking - contact a qualified technician. The pressure switch is restarted automatically when normal operating conditions are resumed - Check operation of cooling unit. Locate which of the following situations caused the device to cut in: 1. Excessive thermal load - resume normal operating conditions. 2. Incoming air is too hot - resume normal operating conditions. 3. Ambient temperature is too high or ventilation is not sufficient - provide sufficient ventilation. 4. The condenser is dirty - clean it. 5. The fan does not work - see relative paragraph. 6. Refrigerating gas is leaking - contact a qualified technician. Restart the thermostat by pressing the button on it - check operation of the cooling unit. The TS thermostat is faulty - replace it. 50 MISTRAL LM 140 BASIC COOLING UNIT