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OPERATION MANUAL

Ultracool chillers

UC 2, UC 4, UC 8, UC 14, UC 24, UC 50, UC 65, UC 80, UC 100

DMI-0217-12

24/11/2022

Read this manual prior to performing any task!

Summary of Contents for UC 2

Page 1: ...OPERATION MANUAL Ultracool chillers UC 2 UC 4 UC 8 UC 14 UC 24 UC 50 UC 65 UC 80 UC 100 DMI 0217 12 24 11 2022 Read this manual prior to performing any task ...

Page 2: ...ersonnel Disposal of Waste Equipment by Users in Private Household in the European Union This symbol on the product or on its packaging indicates that this product must not be disposed of with your other household waste Instead it is your responsibility to dispose of your waste equipment by handing it over to a designated collection point for the recycling of waste electrical and electronic equipm...

Page 3: ... 3 5 Water Connection 14 3 6 Electrical Connection UC 2 and UC 4 15 3 7 Electrical Connection UC 8 to UC 100 15 3 8 Additional Electrical Connections 17 4 Startup 18 4 1 Operating Conditions 18 4 2 Chiller startup 20 5 Chiller Controls 22 5 1 Control and monitoring elements 22 5 2 UC Controller 23 5 3 Operation 24 5 4 Preheating Function 28 5 5 Ethernet Configuration 29 5 6 LAUDA LIVE Cloud servic...

Page 4: ...ssories and consumables 49 10 Log Book 52 10 1 Log Book 52 11 Annexes 53 11 1 Water quality 53 12 EC Declaration of Conformity UC 2 and UC 4 54 13 EC Declaration of Conformity UC 8 to UC 100 55 Attention Points of special interest to keep in mind ...

Page 5: ...r has to observe the national working operating and safety regulations Also existing internal factory regulations must be met Maintenance and repair work must only be carried out by specially trained personnel and if necessary under supervision of a person qualified for this work Protective or safety devices must not be removed modified or readjusted During operation of the water chiller none of t...

Page 6: ...ION Keep the unit upright at all times Do not tilt when shipping or moving The Ultracool unit must be transported by pallet jack or forklift truck 2 3 SITE The Ultracool unit must be installed in an atmosphere where the range of temperatures is within the indicated margins mentioned in point 4 1 It is necessary to add ethylene glycol to the water of the circuit as indicated in point 4 1 The chille...

Page 7: ...be moved forwards to free the access panels when there are maintenance works to be carried out The inlet of fresh air onto the condenser should be in the most direct way possible avoiding any chance of air recycling the ceiling above should not be at less than 1m 40 for UC 8 to UC 24 models and 2m 80 for the UC 50 to UC 100 models UC 2 and UC 4 models do not need any free space above them during o...

Page 8: ...OL UNIT UC 2 AND UC 4 Front of the UC 4 1 Top panel It gives access to the electrical box 2 Main power switch 3 Controller 4 Ventilation grid on both sides warm air exhaust 5 Power and communications cables inlet 6 Four wheels with locking brake 1 2 3 4 5 6 ...

Page 9: ...9 Back of the UC 4 1 Process water inlet connection 2 Process water outlet connection 3 Drain connection inside the unit 4 Condenser cool air intake 5 Characteristics plate 4 5 1 2 3 ...

Page 10: ...UC 24 1 External controller display 2 Status and Warning Alarm LEDs 3 Right panel It gives access to the electrical box 4 Main power switch 5 Power and communications cables inlet below the unit 6 Four wheels with locking brake feet on UC 50 and UC 65 2 3 4 5 6 1 ...

Page 11: ...11 Back of the UC 24 1 Process water inlet connection 2 Process water outlet connection 3 Drain connection 4 Motor fan warm air exhaust 5 Condenser cool air intake 6 Characteristics plate 4 6 5 1 2 3 ...

Page 12: ...00 Front of the UC 100 1 External controller display 2 Status and Warning Alarm LEDs 3 Front panel It gives access to the electrical box 4 Main power switch 5 Condenser cool air intake 6 Power and communications cables inlet below the unit 2 3 6 1 5 4 ...

Page 13: ...13 Back of the UC 100 1 Process water inlet connection 2 Process water outlet connection 3 Drain connection 4 Motor fan warm air exhaust 5 Condenser cool air intake 6 Characteristics plate 5 6 2 1 4 3 ...

Page 14: ...ter lines The length of hose number of fittings valves etc will also cause an increase of the pressure drop Always install thermal insulation for all pipes or at least make sure that the pipes are opaque to the light When possible install the water lines at the same level as the chiller until reaching the application The height difference between the chiller and the application should never exceed...

Page 15: ...able connection if the chiller is connected to a local network via Ethernet or to a Cloud gateway Introduce the Ethernet cable through the brush gland on the right side of the chiller and into the electrical box through the rubber cable holder then connect it to the controller 3 7 ELECTRICAL CONNECTION UC 8 TO UC 100 Operating voltage 400VAC 10 50Hz 3 Ph or 460VAC 10 60Hz 3 Ph In terms of Electrom...

Page 16: ...splay has no IP protection make sure it is installed on a location protected from the weather from dust and from any water splashes If the chiller is controlled remotely it is also possible to remove the display after the initial configuration and store it in a safe location as the chiller does not need it to operate In such a case the end connector of the display s cable also needs to remain prot...

Page 17: ...ed contact chiller On Note The chiller will not turn On unless these terminals are bridged Once the commissioning operation is complete if the remote On Off function described above is not used connect the supplied wire bridge between terminals 23 and 24 to be able to turn the chiller On from the display Terminals 57 and 61 external alarm report signal These terminals provide a dry contact to repo...

Page 18: ... accessory should be installed This typically happens with applications that use a water flow significantly lower than the chiller s nominal flow The external by pass option allows the chiller to work with close to its nominal flow even if the application is only using part of that flow Please note that a flow lower than the chiller s nominal flow can negatively affect the outlet temperature stabi...

Page 19: ...djustment Min Ambient Temperature 32ºF or more Less than 32ºF until 23ºF Less than 23ºF until 5ºF Cold Water Set Point 45ºF or more 0 32ºF 15 23ºF 30 5ºF Less than 45ºF until 41ºF 15 23ºF 15 23ºF 30 5ºF Less than 41ºF until 32ºF 30 5ºF 30 5ºF 30 5ºF Less than 32ºF until 23ºF 30 5ºF 30 5ºF 30 5ºF Less than 23ºF until 14ºF 40 4ºF 40 4ºF 40 4ºF 4 The ethylene glycol percentage is given as measured as...

Page 20: ...e it resets itself when it resets you will hear its contact click While filling the tank make sure no water splashes onto any electrical components Keep the cover of the electrical box closed during the filling procedure Prime the pump to release any air inside Remove the priming plug P see diagram below Keep the priming plug open until only liquid runs out the priming plug Replace the priming plu...

Page 21: ...the compressor will start roughly 2 minutes after switching the main power switch ON If this happens switch the main power switch OFF and perform the operation again within 2 minutes If the compressor works with the lateral panel open the chiller could trip by high pressure alarm see point 7 After 5 minutes or when the unit stops by low water level alarm turn the main power switch OFF open the lat...

Page 22: ... active the chiller is still running It is lit steadily when an Alarm is active either the refrigerant circuit or the complete unit is stopped See point 7 for troubleshooting 3 Main power switch Located on the right side of the chiller It connects and disconnects the Ultracool unit from the power supply 4 Controller display It shows all information on the operation of the chiller and allows contro...

Page 23: ... setpoint and it shows which motors in the chiller are currently running The motor symbols are from left to right the water pump the refrigerant compressor and the motor fan If a motor is running its symbol is lit and if it is stopped its symbol is not shown A blinking symbol means that an Off signal has been received but the motor is still running and it will turn Off shortly it is being delayed ...

Page 24: ...wer Switch was turned Off it will start suddenly next time it is switched back On On Off from the display As long as the remote On Off is connected the chiller can be turned On and Off from the display either the remote display connected to the chiller or the webserver on a connected computer In order to start stop the chiller from the display go to the On Off screen see point 5 2 and use the Up D...

Page 25: ...n and press Enter to access the Units of Measure configuration screen From the new screen press Up or Down to select the Units of Measure to be changed User interface Changes the units of measure used by the display of the chiller both the External controller display and also the Webserver controller display Modbus TCP IP Changes the units of measure used to transmit data through the Modbus TCP IP...

Page 26: ...ternal alarm signal logic The chiller has a dry contact available to report a general alarm of the chiller see point 3 8 To change the logic of this contact closed when an alarm is active or open when an alarm is active go to the Settings screens loop see point 5 2 press Down until the Alarm contact set screen Press Enter to highlight the current contact logic use the Up Down buttons to change it ...

Page 27: ...ol and temperature stability The chiller relies in its ability to adjust the compressor speed to match the cooling capacity required by the application to maintain a high water outlet temperature stability Please note that the compressor has a minimum speed ranging from 15 to 25 depending on the chiller model and specific working conditions When the heat load from the application is lower than the...

Page 28: ... set the temperature go to the Settings screens loop see point 5 2 press Down to access the Preheating set screen press Enter to highlight the current set value use the Up Down buttons to change the value and press Enter again to confirm the new value Please note that the heat generated by the pump is limited and depending on the thermal losses in the whole water circuit it s possible that the tem...

Page 29: ... Use the Down button to select SETTINGS and press Enter to access the Settings menu 3 Use the Down button to select TCP Ipv4 SETTINGS and press Enter to access the IP Configuration screen 4 In this screen use the Enter button to move to the next field and Up and Down to change the values Check with your IT team which values are correct for your local network Once done select the Update config fiel...

Page 30: ... the webserver of the chiller from a web browser on any PC connected to the same network as the chiller To do so just introduce the IP number of the chiller on the navigation bar of the web browser and select the Display tile from the home page ...

Page 31: ...ed access to a power socket and have the antenna placed in a location with good signal reception By default the Ultracool units block the communications with the CLOUD and must be given permission through the display menu explicitly In this menu the permissions are divided between write read and operation service parameters Within this distinction operating parameters are those directly shown to t...

Page 32: ...ith the Unit disconnected Main power switch Off clean the condenser removing dust dirt with a soft brush and or vacuum clean the surface from the outside Do not use any detergents to clean the condenser Clean the housing internally and externally eliminating the dust present especially on the water pump rack Yearly Change the filter element and refill the circuit with water of the required quality...

Page 33: ...nformation screens loop see point 5 2 press Up once and then Enter to access the Log export screen 2 Press Enter and then the Up or Down buttons to select where to save the log file The file can be stored in the chiller s controller Internal Flash Memory or it can be saved to a connected USB drive If using a USB drive connect it to the microUSB port available on the front of the chiller s controll...

Page 34: ... when the service engineer is on site with the chiller they will be able to retrieve the saved log file for analysis Please note that if this process is repeated at a later time the saved log file will be overwritten which could cause the relevant data to diagnose the alarm to be lost If the log file is saved to a USB drive it can then be sent in advance to our service team for analysis This can g...

Page 35: ...ized technical service Disconnect the chiller by turning Off the main power switch see point 5 1 Turn it back On after at least 30 seconds have passed AL165 Alarm freeze evaporating temp Alarm due to low evaporating temperature The evaporation temperature is too low and there is risk of freezing It stops the compressor if it happens 3 times in a short period Water circuit blocked Possible freezing...

Page 36: ... whole unit Level switch did not switch to the full position Water leak in the internal circuit of the UC Water leak in the external water circuit Water leak in the water pump Circuit breaker Q2 has tripped Check that the level switch works properly and that the tank is full enough After disconnecting the Main Power switch open the right panel open the water tank to check the water level UC 50 to ...

Page 37: ...t it does not generate heat and let the chiller without load for some minutes If the problem persists contact authorized technical service It s a warning only the chiller is still working normally AL463 High water temperature Safety Alarm It stops the whole unit The water inlet temperature or water tank temperature has exceeded 45ºC 113ºF Wait until the temperature decreases or change the water in...

Page 38: ...h of the cable for any damages If the cable is damaged contact authorized technical service to replace it Contact authorized technical service The chiller is still running normally and it accepts On Off commands through the 23 24 digital input Other settings and information functions are still available through the Ethernet connection Maintenance request The chiller has exceeded the working hours ...

Page 39: ...ump 50 Hz kW 0 5 0 5 0 75 0 75 0 75 1 5 2 3 4 0 4 0 max l min 42 42 130 130 130 230 250 367 367 min 4 2 4 2 13 13 13 23 25 37 37 max bar 3 4 3 4 4 2 4 2 4 2 4 6 5 0 5 3 5 3 min 1 5 1 5 1 1 1 1 5 2 7 3 3 3 3 Pump 60 Hz kW 0 6 0 6 1 5 1 5 1 5 2 2 4 0 6 0 6 0 max l min 50 50 167 167 167 300 300 450 450 min 5 5 17 17 17 30 30 45 45 max bar 3 5 3 5 6 6 6 6 6 6 6 8 7 2 7 5 7 5 min 1 5 1 5 2 1 2 1 2 1 2 ...

Page 40: ...92 kW Rated power input DA 0 63 kW Rated energy efficiency ratio EERDC A 3 02 Parameters at rating point B Rated refrigeration capacity PB 1 79 kW Rated power input DB 0 41 kW Rated energy efficiency ratio EERDC B 4 37 Parameters at rating point C Rated refrigeration capacity PC 1 66 kW Rated power input DC 0 28 kW Rated energy efficiency ratio EERDC C 6 00 Parameters at rating point D Rated refri...

Page 41: ...ing point B Rated refrigeration capacity PB 3 55 kW Rated power input DB 1 00 kW Rated energy efficiency ratio EERDC B 3 53 Parameters at rating point C Rated refrigeration capacity PC 3 29 kW Rated power input DC 0 68 kW Rated energy efficiency ratio EERDC C 4 85 Parameters at rating point D Rated refrigeration capacity PD 3 04 kW Rated power input DD 0 45 kW Rated energy efficiency ratio EERDC D...

Page 42: ...ing point B Rated refrigeration capacity PB 7 75 kW Rated power input DB 2 01 kW Rated energy efficiency ratio EERDC B 3 84 Parameters at rating point C Rated refrigeration capacity PC 7 19 kW Rated power input DC 1 18 kW Rated energy efficiency ratio EERDC C 6 08 Parameters at rating point D Rated refrigeration capacity PD 6 64 kW Rated power input DD 0 75 kW Rated energy efficiency ratio EERDC D...

Page 43: ...ing point B Rated refrigeration capacity PB 12 51 kW Rated power input DB 3 35 kW Rated energy efficiency ratio EERDC B 3 72 Parameters at rating point C Rated refrigeration capacity PC 11 61 kW Rated power input DC 2 09 kW Rated energy efficiency ratio EERDC C 5 53 Parameters at rating point D Rated refrigeration capacity PD 10 72 kW Rated power input DD 1 09 kW Rated energy efficiency ratio EERD...

Page 44: ...ing point B Rated refrigeration capacity PB 18 95 kW Rated power input DB 5 46 kW Rated energy efficiency ratio EERDC B 3 44 Parameters at rating point C Rated refrigeration capacity PC 17 59 kW Rated power input DC 3 49 kW Rated energy efficiency ratio EERDC C 5 00 Parameters at rating point D Rated refrigeration capacity PD 16 24 kW Rated power input DD 2 00 kW Rated energy efficiency ratio EERD...

Page 45: ...ing point B Rated refrigeration capacity PB 39 48 kW Rated power input DB 10 28 kW Rated energy efficiency ratio EERDC B 3 82 Parameters at rating point C Rated refrigeration capacity PC 36 66 kW Rated power input DC 7 23 kW Rated energy efficiency ratio EERDC C 5 05 Parameters at rating point D Rated refrigeration capacity PD 33 84 kW Rated power input DD 5 06 kW Rated energy efficiency ratio EER...

Page 46: ...ing point B Rated refrigeration capacity PB 51 43 kW Rated power input DB 13 91 kW Rated energy efficiency ratio EERDC B 3 67 Parameters at rating point C Rated refrigeration capacity PC 47 75 kW Rated power input DC 9 77 kW Rated energy efficiency ratio EERDC C 4 85 Parameters at rating point D Rated refrigeration capacity PD 44 08 kW Rated power input DD 6 86 kW Rated energy efficiency ratio EER...

Page 47: ...ing point B Rated refrigeration capacity PB 62 51 kW Rated power input DB 14 94 kW Rated energy efficiency ratio EERDC B 4 18 Parameters at rating point C Rated refrigeration capacity PC 58 04 kW Rated power input DC 9 47 kW Rated energy efficiency ratio EERDC C 6 12 Parameters at rating point D Rated refrigeration capacity PD 53 58 kW Rated power input DD 5 44 kW Rated energy efficiency ratio EER...

Page 48: ...ing point B Rated refrigeration capacity PB 74 67 kW Rated power input DB 19 35 kW Rated energy efficiency ratio EERDC B 3 85 Parameters at rating point C Rated refrigeration capacity PC 69 33 kW Rated power input DC 12 49 kW Rated energy efficiency ratio EERDC C 5 54 Parameters at rating point D Rated refrigeration capacity PD 64 00 kW Rated power input DD 7 29 kW Rated energy efficiency ratio EE...

Page 49: ...valve A001514 RCP Remote Control Panel For installation away from the unit Cable length 10 metres electrical protection IP40 A001561 1 BSP Rp G parallel thread Accessories for UC 2 and UC 4 230V 1Ph 60Hz NPT 2 Catalogue number IK10 2x10m Installation Kit Includes 2 hoses and 2 sets of fittings A001515 IK20 2x20m Installation Kit Includes 2 hoses and 2 sets of fittings A001516 EB External by pass R...

Page 50: ...isplay It replaces the one that comes with the chiller It s suitable for outdoor installation A001560 Accessories for UC 50 and UC 65 Catalogue number IK10 2x10m Installation Kit Includes 2 hoses and 2 sets of fittings A000003 IK20 2x20m Installation Kit Includes 2 hoses and 2 sets of fittings A000006 IK50 2x50m Installation Kit Includes 2 hoses and 2 sets of fittings A000008 BSP NPT Adapters 2 fi...

Page 51: ...the one that comes with the chiller It s suitable for outdoor installation A001560 Approved liquids Catalogue number 2L Refrifluid B 1 Concentrated bactericide and anticorrosive additive E7011852 4L Refrifluid B 1 Concentrated bactericide and anticorrosive additive E7011854 25L Refrifluid 1 2 Water ethylene glycol mixture including Refrifluid B E7012402 50L Refrifluid 1 2 Water ethylene glycol mix...

Page 52: ...52 10 LOG BOOK 10 1 LOG BOOK Date Remarks Signature ...

Page 53: ...ppm Total iron ions Fe2 and Fe3 0 2 ppm Chloride Cl 300 ppm H2S 0 05 ppm Solid particles 150 m Ethylene glycol Max 40 The Total Hardness is specified in ppm mg L of Ca2CO3 Please note that ultra pure waters like deionized water can also be harmful for some of the materials of the Ultracool units as they have a conductivity below 50 S cm Do not use automotive antifreeze Use lab grade ethylene glyco...

Page 54: ...relating to machinery 2006 42 EC EMC Electromagnetic Compatibility 2014 30 EU Low voltage Directive 2014 35 EU Eco design Directive 2009 125 EC The safety objectives of the Machinery Directive in regard to electrical safety were adhered to in accordance with Annex I Paragraph 1 5 1 by its conformity with the Low Voltage Directive 2014 35 EU Directive 2011 65 EU 2015 863 EU Defined by restriction o...

Page 55: ...re applied Directive relating to machinery 2006 42 EC EMC Electromagnetic Compatibility 2014 30 EU Low voltage Directive 2014 35 EU Eco design Directive 2009 125 EC The safety objectives of the Machinery Directive in regard to electrical safety were adhered to in accordance with Annex I Paragraph 1 5 1 by its conformity with the Low Voltage Directive 2014 35 EU Directive 2011 65 EU 2015 863 EU Def...

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