Mounting and Operating Manual for Water Chiller Typ BR

Transcription

1 Mounting and Operating Manual for Water Chiller Typ BR Deckblatt BR e.doc/ausgabe

2 Achtung Geräte zur Reparatur müssen stets ohne Tankinhalt verschickt werden,da sonst die Entleerung und Entsorgung in Rechnung gestellt wird. Attention Repair machines tanks always need to be emptied. remaining fluids,which need to be discharged by the supplier, will be Charged.

3 Attention! Load all 4 jack rings equal! Using only 2 jack rings is not allowed! There is a speed control for the fan included in this unit. You may not use the unit with a generator, because there will be any incompatabilitys!

4 Achtung! Durch den Einbau eines Zeitrelais, kommt es beim Einschalten am Hauptschalter des Kühlers zu einer Stillstandzeit von 4 Minuten! Während dieser Zeit bringt der Kühler keine Kühlleistung! Während dieser Zeit kann es zu einer Störmeldung kommen! Attention! There is a time lag relay included in this unit. With this relay the unit is not working until 4 minutes by switching on the emergency line switch! There is no cooling capacity until this time! There will be fault signals until this time!

5 Note: The mounting and operating manual must not be partially or completely duplicated, neither disseminated nor unauthorized exploited in order to compete or to impart its contents to anyone. Any offences claim damages. All rights reserved. The operators of refrigeration, air conditioning and heat pump systems are required, to make a periodic tightness testing by certified personnel at specific time intervals. The period depends on the quantity of refrigerant and vary between a year (from 3 kg or 6 kg in hermetic systems), 6 month (30 kg) and 3 month (from 300 kg); Directions for Use: Construction and technical dates are subject to change without notice in order to ensure further development. There is no possibility to lay claim to any specifications, illustrations, drawings or descriptions. Errors excepted! Please get all necessary information about mounting, setting, operation and maintenance before starting-up the unit. Directions for safety: Before removing unit caps : set unit potential-free. it should be, there are hot surfaces at copper-tubes or the compressor. you should prove, the fan is not running anymore. If the fan stops you can repair the unit or do any maintenance.

6 Table of Contents 1 UNPACKING AND HANDLING 4 2 GENERAL STATEMENTS 4 3 TECHNICAL DATA AND TYPE PLATE 4 4 APPLICATION AND FUNCTION 5 5 MOUNTING INSTRUCTIONS INSTALLATION HYDRAULIC CONNECTION ELECTRIC CONNECTION 5 6 START-UP AND OPERATION PREPARATION START-UP NUMBER OF OPERATIONS OF THE COMPRESSOR 6 7 OPERATING THE MULTI-STEP CONTROLLER FUNCTIONAL CHARACTERISTICS ADJUSTMENT OF TARGET TEMPERATURE ADJUSTMENT OF EXCESS OR INSUFFICIENT TEMPERATURE SENSOR DEFECT 8 8 MAINTENANCE 9 9 GUARANTEE PROVISION 9 10 HOW TO PUT UNIT OUT OF ACTION IN CASE OF INCIDENT: WHAT TO DO IF

7 ANNEX 1 Technical Data Sheet 2 Dimension Sheet 2.1 WRK Accessories Connection Flexible Tubes 2.2 Setup 3 System Scheme 4 Pump Performance Characteristics 5 Wiring Diagram Main Circuit 5.1 Wiring Diagram Control Circuit 5.2 Wiring Diagram Control Circuit 5.3 Wiring Diagram Control Circuit 5.4 Connector Scheme 5.5 Electrical Parts List 6 Trouble Help Table 7 Spare Parts Recommendation 8 Chemical Demands on Circuit Refrigerating Water

8 1 Unpacking and Handling Before and whilst unpacking the unit please check if any damages were caused during transport (especially loose parts, dents, scratches etc.) The carrier has to be informed of any damages immediately. (Please note "Regulation of Damages"). In any case the "General Conditions for Delivery and Service" of the ZVEI (Zentralverband der Elektrotechnischen Industrie, Frankfurt/M.) are valid in their latest wording. Please check the packing material very carefully before disposing it. There might be still any small parts in it. To work on any claim we need details about defects (e.g. photo) as well as type marking and serial number of the unit. The unit has to be transported and stored in operating position only. This is to protect from any damages. If this condition is not being observed there will be no guarantee at all. 2 General Statements In case of transport we advise to empty the liquid container. The unit has to be held in operating position at any time of handling. All work on the water chiller may be performed by skilled personnel only. All relevant safetyand environment protection regulations must be adhered to. The units were constructed considering DIN EN 292, DIN EN 294, DIN EN , DIN EN and UVV-VBG 20. The density of the unit has been checked in the factory. We herewith confirm that the unit went through an electrical security check in the factory before delivery. So, according to UVV VBG 4, 5 (4) there is no commitment for the seller to check the electrical installation of the unit and its condition before the first start-up. 3 Technical Data and Type Plate For installation and maintenance please follow instructions on type plate. You will find them at the side of the unit. Please find technical data in our annex

9 4 Application and Function The water chiller is a compact chiller which has to be installed electrically and hydraulically only. It can be activated immediately after filling in the primary medium. Cooling of the primary medium will be effected in an isolated open box by a plate heat exchanger. Heat that was absorbed by refrigerants in the vaporizer will be emitted to the environment by the aircooled condenser. The unit recools liquid media, e.g. water or brine for industrial or commercial machines, works or processes. There is no authorization for another use or beyond it. Operating the unit with water temperature below <12 C requires antifreeze in adequate dosage to avoid damage caused by freezing up, preferably Antifrogen N. Please note that though the insert limit extends downwards the refrigerating capacity changes considerably. Moreover the pump capacity has to be checked. Please consult an expert before reorganizing! 5 Mounting Instructions 5.1 Installation The unit is to be installed at its place of destination in an accessible way to the side connections. We recommend at least about 1,00 m distance to other units. The unit is to be installed on an absolutely level horizontal surface with adequate load bearing capacity. Please ensure that the cooling air can circulate in a free way. Any air- or exhaust shafts need to be self-priming, i.e. having a compensating fan. 5.2 Hydraulic Connection Connection and running of the liquid lines have to be done by an expert who considers technical rules only. 5.3 Electric Connection The cooling unit is to be connected electrically by the wiring diagram (see annex)

10 The direction of rotation is to be controlled at the axial fan. If the direction of the rotation is wrong please exchange phase at the net line (exchange L1 and L2!). Protection is to be planned according to the current taking in of the unit (see technical data on type plate). ATTENTION: Supply voltage and power frequency must correspond with the rated value which is stated on the type plate of the unit. Any work at electrical systems have to be done by experts only. Please note relevant local security regulations. 6 Start-up and Operation 6.1 Preparation Fill buffer store and primary circle with water (mark "water fill installation"). Read water level from level indicator at the front of the unit. Check all electric connections. Control setting of temperature controller. Setting by the factory is 18 C. 6.2 Start-up Switch-ON master switch ATTENTION: Circulating pump starts working immediately after switching-on the unit. Start the unit after filling in the primary medium only. Never start circulating pump in dry condition!!! Soon after starting it is necessary to check if there is any need to fill in more primary medium. During working temperature the density of all screwings should be checked carefully. 6.3 Number of operations of the compressor After adjustment of the target temperatures, control the number of operations of the compresor. A maximum of 10 operations per hour should not cross over! There is danger of heavily damage! In case of doubt please refer to an expert

11 7 Operating the Multi-Step Controller The multi-step controller serves to regulate - temperature controller of the primary medium - disturbing signal "excess temperature" - disturbing signal "insufficient temperature" 7.1 Functional Characteristics The electronic controller shows the temperature determined by the sensor in the buffer store and compares it to the rated value. Depending on the temperature the original relays - 1 temperature controller of the primary medium - 2 disturbing signal "excess temperature" - 3 disturbing signal "insufficient temperature" will be activated according to the rated values adjusted before. The operating states are notified by LED s. The actual temperature is indicated automatically, the target temperature is shown on display by using the SET-button. The multi-step controller is subdivided in several adjustment levels. 7.2 Adjustment of Target Temperature (Level 1 = Standard working level) All connections have to be established and the buffer store has to be filled. Adjusting the temperature Switch-ON master switch. The display shows e.g. 16,4 C = actual temperature of the medium in buffer store Push SET-button and hold on. The display shows e.g. 19,0 C = target value adjusted before Wanted target value 20 C. Push -button additionally until 20 C is shown on display. Release both buttons. Now display shows 16,4 C again. Pushing -button means increase of temperature. Pushing -button means decrease of temperature. As the factory adjusted a difference of 1 K the sensor now starts the solenoid valve at 20 C, i. e. opening. At the same time the red LED1 is flashing. When a temperature of 19 C is reached the solenoid valve stops, i. e. closing, and the LED1 stops flashing

12 7.3 Adjustment of Excess or Insufficient Temperature (Level 2) Adjustment of the absolute set point, set point limit and hysteresis. Change within this level: Simultaneously push button and for about 5 secs.! Same procedure when leaving this level! Parameter Description C adjustment sector C1 absolute set point 18 C C2 temperature limit (maximum) 25 C C3 temperature limit (minimum) 15 C C5 value of hysteresis of the 0, K 2 K absloute set point C6 value of hysteresis of the 0, K 1 K upper temperature limit C7 value of hysteresis of the 0, K 1 K lower temperature limit C9 lower maximum adjustment limit 14 C of the absolute set point C10 upper maximum adjustment limit 26 C of the absolute set point C11 lower maximum adjustment limit 14 C of the upper temperature limit C12 upper maximum adjustment limit 26 C of the upper temperature limit C13 lower maximum adjustment limit 14 C of the lower temperature limit C14 upper maximum adjustment limit 26 C of the lower temperature limit 7.4 Sensor Defect If sensor is damaged by broken cable or loose supply terminal display will show following: F 1H flashing. If short circuit occurs display will show "F 1L" flashing.the controller relay 1 stops the cooling unit and LED1 stops flashing. The adjusted parameter will be stored by the controller and changed only after a new input. The value stored will be preserved no matter whether the water chiller is turned off or a power failure occurs

13 8 Maintenance Turn off current before doing any maintenance at the cooling unit. Check condition of the primary medium at regular intervals. Refilling of the medium might be necessary. We advise to check the density of the screwed connection in the primary circuit regularly. Especially if primary medium is missing frequently. Wipe off dust and dirt from the lamina of the condenser regularly. Cleaning interval depends on the environmental conditions at the standing place. For normal soiling it will be sufficient to sweep or clean with compressed air. ATTENTION: Do not damage the lamina of the condenser whilst cleaning them. Please note that regular check and maintenance as directed belongs to the correct use of the unit. 9 Guarantee Provision Within the legal time limit we guarantee to eliminate any functional defects inland free of charge as long as they were caused by insufficient workmanship or faulty material. International we only take over the material costs. Further claims, especially following defects are out of the question. We do not guarantee for damages or functional defects caused by improper handling or disregard of the operating manual. Guarantee will be cancelled if there is any interference in the system or if the serial number of the unit is changed or made unrecognizable. The unit was checked and adjusted very carefully in the factory. Nevertheless if you have any complaint please refer to your trusting party for an agreement. Please do not forget to leave the name of your competent official clerk or technician. To maintain the guarantee please note the following: Enclose your letter a detailed description of the defect. Enclose a copy of the invoice or delivery note as reference verification. There note unit type and manufacturing number

14 10 How to put unit out of action We advise to empty primary medium if the unit is out of action for a longer period of time. We do not accept liability for any freezing damages. 11 In case of incident: what to do if... If there is any trouble during operation of the unit you will find help from table of enclosure 6. In case of doubt please refer to an expert

15 Annex

16 Annex 1: Technical Data Sheet Type BR no of item rated refrigerating capacity kw 7,5 water temperature C 18 rated volume current water circuit dm³/min 13 1) ambient temperature at rated operation C 42 air volume current at condenser m³/h 3240 ambient temperature min/max C/ C 10 / 42 controll-thermostat, ON/OFF C/ C 19 / 17 admissible operation overpressure bar 23 high pressure controller OFF/ON bar/bar 23 / 17 refrigerant type/amount -/kg R134a / 5,4 primary medium -/- drinking water content of tank dm³ (l) 150 excess pressure from 1 m distance db(a) 70 electrical characteristic data rated voltage V 400/3/PE rated frequency Hz 50 rated consumption kw 5,16 rated current consumption A 8,57 protective system IP44 measurements height mm 1697 width mm 750 depth mm 800 structural weight kg ~ 230 connector of water for outlet G1 connector of water for inlet G1 1) see annex 4 pump performance characteristic Attention: water-admixtures (e.g. glycols) change data of rated capacity!

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21 Anlage 4 / annex 4 Pumpenkennlinie TC 40/340 pump performance characteristic Förderhöhe / lift of pump [m] Förderstrom / delivery volume [dm³/min] File: TC Diagramm 2 Stand 04-99

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29 Annex 6: Trouble Help Table unit is not working trouble reason removal refrigerating aggregate is working but there is insufficient refrigerating capacity cut-off of high-pressure low pressure cut off cut-off of compressor a) curent supply disturbed b) main switch in OFF-position a) ambient temperature out of limit b) dirty condenser c) lack of refrigerant d) circulating pump is not working correctly e) amount of water too small a) ambient temperature too high b) failure of condenser-ventilation c) dirty condenser a) adjustment min. temperature too low b) controller damaged c) lack of refrigerant response of power circuit breaker or internal winding protection a) check main fuse b) make electric mains c) switch ON main switch a) check ventilation of aggregate b) remove dirt c) instruct expert to refill refrigerant (leakage?) d) check circulating pump e) refill water f) instruct expert to check refrigerating system a) better ventilation b) check condenser-ventilation c) clean condenser a) correction of adjustment min. temperature b) check controller c) Refer to an expert! overheated compressor. Refer to an expert! cut-off of pump response of power circuit breaker overheated pump motor. Refer to an expert!

30 Annex 7: Spare Parts Recommendation unit type BR Item no recommendedamount ME designation 1 designation 2 order no. 1 piece compressor for R134a MTZ piece pump MHI piece axial fan FE050-SDK.4F piece multi controller with sensor MPR piece contactor 3 RT1016-2AP piece contactor 3 RT1017-2AP

31 Aspect: colourless, clear, free from oil and grease Water constituents + caracteristic values Unit ph-value under consideration of the SI-index 7 to 9 Saturation index (SI) (Delta ph-value) - 0,2 < 0 < + 0,2 Total hardness of water dh < 6 Conductivity müs/cm Filtered substances mg/l < 30 Chlorides mg/l < 100 Free chlorine mg/l < 0,5 Hydrosulphide H2S mg/l < 0,05 Ammonia (NH3/NH4+) mg/l < 2 Sulphate mg/l < 100 Hydrogen carbonate mg/l < 300 Hydrogen carbonate / Sulphate mg/l > 1 Sulphide mg/l < 1 Nitrate mg/l < 100 Nitrite mg/l < 0,1 Dissolved ferrum mg/l < 0,2 Manganese mg/l < 0,1 Free aggressive carbon acid mg/l < 20

32 EG - Konformitätserklärung im Sinne der EG-Richtlinie Declaration of Conformity as per EC Directive Maschinen / Machines 89/392/EWG, 91/368/EWG, 93/44/EWG, 93/68/EWG Elektromagnetische Verträglichkeit (EMV) / EMC 89/336/EWG, 91/263/EWG, 92/31/EWG, 93/68/EWG Niederspannung / Low voltage 73/23/EWG, 93/68/EWG Druckgeräte / Pressure equipment 97/23/EG Das Gerät/die Geräte des Typs The unit(s) of the types AC, BL, BR, CH, LM, OKM, UC, OC wurde entwickelt, konstruiert und gefertigt in Übereinstimmung mit den o.g. EU-Richtlinien, in alleiniger Verantwortung von is/are developed, designed and manufactured in conformity with the EC Directives and in responsibility of Lahntechnik GmbH Taunusstr. 10 D Nassau/Lahn Germany Angewandte harmonisierte Normen Applied harmonized standards DIN EN 292, Safety of machinery, devices and systems DIN EN 294, Safety of machinery DIN EN 378 part 1-4, Refrigerating systems and heat pumps - Safety and environmental requirements DIN EN , Electrical equipment of machines DIN EN 60335, Household and similar electrical appliances - Safety DIN EN 55014, Electromagnetic compatibility - Requirements for household appliances, electric tools and similar apparatus DIN EN 50081, Electromagnetic compatibility DIN EN 50082, Electromagnetic compatibility DIN EN 60555, Electromagnetic compatibility / Disturbances in supply systems caused by household appliances and similar electrical equipment IEC 801, Electromagnetic compatibility / Interference immunity Nationale Normen und Spezifikationen National standards and specifications DIN 8975, Refrigerating plants - Safety principles for design, equipment and installation DIN 31001, Safety devices DIN part 35, Measurement of noise emitted by machines BGR 500 chapter 2.35, Operation of refrigerating systems, heat pumps and cooling systems BGV A3, Operation of electrical installations BetrSichV, German Ordinance on Industrial Safety and Health GSGV 9., German Device Safety Act Henri Junck, Managing Director,