Pfannenberg EB 210 Series Operating And Maintenance Instructions Manual Download

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Operating and Maintenance
Instructions

Chiller

Series EB 210 - EB 440

Version 1.0, June 2019

Summary of Contents for EB 210 Series

Page 1: ...Operating and Maintenance Instructions Chiller Series EB 210 EB 440 Version 1 0 June 2019 ...

Page 2: ...illers The information is presented in a brief clearly arranged format The chapters are numbered throughout Various unit types may be documented in this operating manual Pfannenberg chillers are subject to continuous improvement Please understand that we must reserve the right to changes in design equipment and technology For this reason no claims to specific features of the unit can be derived fr...

Page 3: ...it main components 12 3 3 2 Hydraulic circuit main components 12 3 3 3 Safety and protection devices 13 3 3 4 Main switch 13 3 3 5 Control unit Display 13 3 3 6 Connections 13 3 4 Electrical and mechanical components 14 4 Technical data 15 4 1 Application limits 15 4 1 1 Ambient temperature limitation 15 4 1 2 Voltage limitations 15 4 2 Type label 15 4 3 Technical data sheet short form 16 4 4 Cool...

Page 4: ...raulic circuit 32 5 5 1 Process Water Fluids 32 5 5 2 Corrosion protection 33 5 6 Connecting the chiller to the power supply 34 6 Commissioning 35 6 1 Preparation before switching on the chiller 39 6 2 Switch on chiller 40 6 3 Stop and switch off chiller 40 7 Operating 41 7 1 Carry out settings 41 7 2 Starting the chiller after an interruption 41 7 3 Stop chiller and switch it OFF 41 8 Troubleshoo...

Page 5: ...r is a cooling unit that extracts heat from a liquid by means of a vapor compression refrigeration cycle The cooled liquid is referred to as a coolant and is used for heat removal of liquid cooled components The heat absorbed by the customer application of the components is discharged to the environment on the warm side of the refrigeration cycle The chillers described in this manual are intended ...

Page 6: ...ardous situation in connection with electrical voltage Severe irreversible injuries or death will occur if this notice is not observed WARNING Identifies an exceptionally hazardous situation Severe irreversible or deadly injuries could occur if this notice is not observed CAUTION Identifies a hazardous situation Minor or moderate injuries could occur if this notice is not observed NOTICE Notice is...

Page 7: ... the electrical mains in accordance with the standard EN 60204 and all other applicable national regulations It is also mandatory to comply with Regulation EU No 517 2014 of the European Parliament and of the Council of 16 April 2014 on certain fluorinated greenhouse gases The above mentioned Regulation lays down specific measures and restrictions to be considered while commissioning operating mai...

Page 8: ...ctionality of High Pressure Switch Release pressure before maintaining or servicing the refrigeration circuit Due to toxicity of refrigerant and oil still inside circuit it is recommended to use suitable gloves and mask while servicing refrigerant equipment CAUTION Pressurized device Cooling water glycol mixture under pressure within hydraulic circuits max pressure indicated on chiller data label ...

Page 9: ...OTICE For environmental reasons never discharge refrigerant into atmosphere follow local regulations to properly dispose of refrigerant It is recommended to familiarize with all technical documentation provided with the unit such as Controller manual Hydraulic Electric diagrams to avoid improper operation of this unit 2 2 Safety instructions for auxiliary and operating materials 2 2 1 Glycol Get f...

Page 10: ...in this manual is clearly indicated to switch off the unit before doing any maintenance or control operation protection elements of the unit as fixed panels are not provided with safety devices that block the operation of the unit if they are not mounted in that case the operator could be exposed to contact with internal rotating parts In case of damage of fans protection grids possible risk for t...

Page 11: ... Compressor 2 Air cooled condenser with fan 3 Expansion valve 4 Evaporator 5 Pump 6 Tank Refrigerant circuit The compressor 1 compresses the refrigerant under high pressure The temperature increases This heat is released to the ambient air in the condenser 2 The refrigerant liquefies The condenser fan draws ambient air through the condenser 2 and releases it to the environment A pressure drop occu...

Page 12: ...rigerant charge of the evaporator and is factory set for each unit A change in the setting is only to be carried out by appropriate specialist personnel Evaporator The evaporator used is a plate heat exchanger This ensures the heat exchange between the coolant and the refrigerant and consists of copper brazed stainless steel plates 3 3 2 Hydraulic circuit main components Pump As standard periphera...

Page 13: ...es as a safety device to disconnect the chiller from the power supply 3 3 5 Control unit Display The built in controller takes over all relevant functions to ensure the operation of the chiller These include the function of the cooling circuit the function of the hydraulic circuit and the transmission of error messages Depending on the device configuration the controller may differ in design and f...

Page 14: ...g GmbH Page 14 50 EN 3 4 Electrical and mechanical components Refrigeration and hydraulic circuits are accessible by removing the two lateral panels Compressor Condenser Dehydrator Filter Sight glass High pressure switch Low pressure switch Thermostatic Valve Evaporator Fan Pump ...

Page 15: ...erg standard chiller operation is guaranteed within these ranges Nominal voltage 10 V Nominal frequency 1 Hz Please refer to the type label to see the nominal operating conditions of the unit Nominal conditions V min V V max V f min Hz f max Hz 230 V 1 50 Hz 207 253 49 5 50 5 230 V 1 60 Hz 207 253 59 4 60 6 400 V 3 50 Hz 360 440 49 5 50 5 460 V 3 60 Hz 414 506 59 4 60 6 NOTICE Special voltage For ...

Page 16: ...edium 1 1 BSP Sound pressure 1m 50 Hz EN ISO 3741 64 70 dB A Weight without packaging 389 403 kg E box degree of protection EN 60529 IP54 IP54 Colour RAL7035 RAL7035 EB 310 WT B EB 360 WT B Unit Rated voltage 400 3 50 460 3 60 400 3 50 460 3 60 V Hz Cooling capacity with pump 1 30 6 36 7 35 6 42 7 kW Flow rate pump 82 98 90 107 l min Pump pressure 2 5 2 5 bar Ambient temperature 15 45 15 45 C Targ...

Page 17: ...5 2 5 bar Ambient temperature 15 43 15 43 C Target value tolerance 2 2 K Refrigerant R407C R407C Max power consumption 18 1 21 8 19 1 23 kW Max current consumption 31 5 33 34 5 35 A Starting current 131 1 134 5 142 9 146 6 A Control voltage 24 AC 24 AC V Airflow external 12 000 12 000 m h Tank volume 200 200 l Connections medium 1 1 BSP Sound pressure 1m 50 Hz EN ISO 3741 72 74 dB A Weight without...

Page 18: ...ge 18 50 EN 4 4 Cooling performance curve 4 4 1 EB 210 to 440 4 4 2 Correction factors Ambient air temperature C 15 20 25 30 32 35 40 45 Cooling capacity 1 095 1 09 1 08 1 03 1 0 95 0 87 0 79 Ethylene glycol Propylene glycol 20 30 50 20 30 50 Cooling capacity 0 99 0 98 0 96 0 99 0 98 0 96 ...

Page 19: ...Operating and Maintenance Instructions Chiller Series EB 210 EB 440 Pfannenberg GmbH Page 19 50 EN 4 4 3 Chiller envelope ...

Page 20: ...Operating and Maintenance Instructions Chiller Series EB 210 EB 440 Pfannenberg GmbH Page 20 50 EN 4 5 Pump performance curve 4 5 1 EB 210 4 5 2 EB 260 ...

Page 21: ...Operating and Maintenance Instructions Chiller Series EB 210 EB 440 Pfannenberg GmbH Page 21 50 EN 4 5 3 EB 310 4 5 4 EB 360 ...

Page 22: ...Operating and Maintenance Instructions Chiller Series EB 210 EB 440 Pfannenberg GmbH Page 22 50 EN 4 5 5 EB 410 4 5 6 EB 440 ...

Page 23: ...hx X 8 Anti freeze thermostat X 9 Pump X 10 Manometer X 11 Tank cap vented X 12 Level indicator X 13 Drain valve ball X 14 Tank X 15 Temperature probe coolant supply temperature X BPH Hydraulic bypass adjustable X Controller Digital controller X HP High pressure switch X LP Low pressure switch X PS Pressure sensor X Options 16 External temperature probe reference temperature X BPG Hot gas bypass s...

Page 24: ...Operating and Maintenance Instructions Chiller Series EB 210 EB 440 Pfannenberg GmbH Page 24 50 EN 4 7 Dimensional drawing 4 7 1 EB 210 to 260 Dimensions ...

Page 25: ...Operating and Maintenance Instructions Chiller Series EB 210 EB 440 Pfannenberg GmbH Page 25 50 EN 4 7 2 EB 310 to 440 Dimensions ...

Page 26: ...ructions Chiller Series EB 210 EB 440 Pfannenberg GmbH Page 26 50 EN 4 7 3 EB 210 to 260 Connection Chiller Model Hydraulic connection EB 210 to 260 1 4 7 4 EB 310 to 440 Connection Chiller Model Hydraulic connection EB 310 to 440 1 ...

Page 27: ...intenance Instructions Chiller Series EB 210 EB 440 Pfannenberg GmbH Page 27 50 EN 4 8 Minimum distance from obstacles or other objects Chiller model A mm B mm C mm D mm E mm EB 210 to 440 1 000 1 000 1 500 1 500 1 500 ...

Page 28: ...unit in the position of use Always transport the unit using the packaging provided by the factory The packaged chillers are not suitable for piling up on top of each other 5 2 Unpack the chiller WARNING Danger of accidents due to the heavy weight of the units Uncontrolled movements of the unit during assembly can cause accidents Use suitable lifting equipment and secure unit to prevent accidents A...

Page 29: ...nischen Industrie Central Association of the Electrical Engineering and Electronics Industry in Germany according to the latest revision apply Each chiller is supplied on a wooden pallet wrapped with protective film strapped and protected on lateral sides rain film protection Store the chiller in a dry place away from heat sources All waste materials should be recycled in the appropriate manner Fo...

Page 30: ...uately dimensioned lifting beam provided by the customer Minimum requirements of lifting pipes Diameter 33 7 mm Thickness 5 mm Material S355JR 1 0045 NOTICE Leakage or improper function due to loosen parts junctions Check after the final positioning of the chiller the internal connections to avoid damage during operation ...

Page 31: ... 4 Connect the chiller to the hydraulic pipes For proper operation of the unit the following minimum requirements for the hydraulic circuit must be observed The chiller has been cleaned by means of specific cleaning products Make sure that the pipes used do not contain dirt or processing residues if in doubt perform one or more cleaning cycles Install a filter on the chiller inlet return pipe with...

Page 32: ...s Do not use automotive antifreeze The inhibitors used in automotive antifreeze can break down quickly and accelerate the degradation of the coolant base glycol as well as promote corrosion in a system Silicates used in automotive antifreeze coat heat exchangers resulting in reduced heat transfer Also silicates can gel causing fouling and plugging of a system The ratio of inhibited glycol to water...

Page 33: ...3 15 PP50E 50 25 108 38 CAUTION Malfunction due to glycol concentration The higher the concentration of glycol the lower the amount of heat rejection you will be able to get out of the fluid CAUTION Safety issues due to wrong glycol selection Ethylene glycol Pfannenberg Protect PP E and Propylene glycol Pfannenberg Protect PP P differs for viscosity and toxicity Ethylene glycol is less viscous tha...

Page 34: ...ately earthed In case of outdoor installation it is strictly recommended to follow the local regulation for the proper protection of the system unit piping against lightnings Check that the voltage and frequency of the power supply correspond to the specifications on the unit s data plate and or enclosed Electrical diagram Pfannenberg chiller units are designed for TN Earthing Systems Use the Maxi...

Page 35: ... to prevent re connection Test to ensure the absence of voltage on the unit DANGER Life threatening danger due to refrigerant under pressure or high low refrigerant temperature Work on refrigerant circuits must be carried out exclusively by trained qualified personnel CAUTION Coolant under pressure Work on hydraulic circuits must be carried out exclusively by trained qualified personnel CAUTION Un...

Page 36: ...Operating and Maintenance Instructions Chiller Series EB 210 EB 440 Pfannenberg GmbH Page 36 50 EN Power connection chiller without cable Power connection chiller with Harting connector ...

Page 37: ...tation Please note that there is an arrow located at the back part of the pump for direction indication CAUTION Damage due to incorrect pump operation The pump must not run dry or in inverse direction therefore the checking of the correct rotation must be quick In case of wrong rotation turn the main switch 1 immediately to the 0 OFF position Swap two phases R S T on the terminal board of the elec...

Page 38: ...he thermostat s pressure switch es or other components of the refrigerating circuit must be performed by qualified personnel of the PFANNENBERG Service only For further information on chiller installation start up or troubleshooting please contact the PFANNENBERG Sales Support NOTICE Quick commissioning For a quick commissioning instruction please see appendix Step by step instruction ...

Page 39: ...connected delivery side cold water return side warm water Water filter if present is clean and the package of filter cartridge has been removed Tank is filled to max level of visual level indicator Tank cap is present and tightened Hydraulic pipes are installed at the right position in accordance with INLET OUTLET identification plates and connections are tightened The pump has been properly purge...

Page 40: ...ll functions After this the controller will start the chiller operation automatically CAUTION Start up behavior of common alarm for chillers with Eliwell SMP controller After the main power supply is turned ON the common alarm contact dry contact is open as long as the controller is running the boot sequence If after the boot sequence no error occurs the common alarm contact will switch to close p...

Page 41: ...ponding parameters For detailed description of how to change parameters please check the enclosed Controller manual 7 2 Starting the chiller after an interruption CAUTION Undefined operating status To avoid an undefined operating status a functional restriction or a device fault after switching OFF the chiller wait for about 30 seconds before turning it ON again 7 3 Stop chiller and switch it OFF ...

Page 42: ... low refrigerant temperature Work on refrigerant circuits must be carried out exclusively by trained qualified personnel DANGER Life threatening danger due to toxicity of refrigerant coolant and oil Work on refrigerant circuits must be carried out exclusively by trained qualified personnel Work on hydraulic circuits must be carried out exclusively by trained qualified personnel CAUTION Coolant und...

Page 43: ...ong set point Change cooling setpoint Controller manual Lack of refrigerant Please ask for the service by a refrigeration engineer TD function active set point temperature follows the ambient temperature Deactivate the TD function if not required Controller manual Too much heat load Possible wrong application to be checked with our staff Compressor does not start The compressor protection KLIXON w...

Page 44: ...en fan Replace the fan Reversed fan rotating direction Verify the connection on the terminal board of the electrical box Ambient temperature too high Provide adequate ventilation with air at max or lower temperature as specified Set up the chiller in a colder place Water setpoint too high in combination with high ambient temperature Reduce the water temperature set point Chiller operating without ...

Page 45: ... in the limits indicated on the type label or in chapter Technical data If the chiller is equipped with an air filter the filter has to be changed cleaned monthly or if required in a shorter time interval Do a visual inspection of the condenser monthly on the external side to see whether it is clean or not The fins of the condenser must not have any dust deposits or residual products or sludges on...

Page 46: ...n circuit thus no further inspection from notified bodies is required according to D M nr 309 December the 1st 2004 The customer is obliged to comply with all additional local requirements NOTICE Safety discharge valve It is necessary to replace safety discharge valve after it has triggered The safety discharge valve is no longer covered by the warranty after the first activation ...

Page 47: ...r of accidents due to the heavy weight of the units Uncontrolled movements of the unit during decommissioning can cause accidents Use suitable lifting equipment and secure unit to prevent accidents Also secure assembled components CAUTION Danger of injury due to sharp edges For manufacturing reasons the metal edges of the unit may have burrs Wear gloves during service and assembly work If units ar...

Page 48: ...ons Chiller Series EB 210 EB 440 Pfannenberg GmbH Page 48 50 EN 11 Warranty For information about warranty please visit Pfannenberg website http www pfannenberg com en company general conditions 12 Appendix 12 1 Step by step instruction ...

Page 49: ...pen Court Bessemer Way Centurion Business Park S60 1FB Templeborough Pfannenberg France S A R L 30 rue de l industrie 92500 Rueil Malmaison 39 0524 516711 39 0524 516790 service pfannenberg it www pfannenberg it 44 1709 364844 44 1709 364211 service pfannenberg co uk www pfannenberg co uk 33 1 47 08 47 47 33 1 47 08 47 48 service pfannenberg fr www pfannenberg fr Singapore India Russia CIS Pfannen...

Page 50: ... EN Liability disclaimer All information contained was thoroughly checked 2019 However we make no guarantee as to the completeness and correctness of the specifications Legal notice Pfannenberg Europe GmbH Werner Witt Straße 1 21035 Hamburg Tel 49 40 734 12 0 www pfannenberg com Pfannenberg 2019 ...

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