Riedel P030 Operating Manual Download

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Original

454522.68.07-01-E

12.02.0032

OPERATING MANUAL

P030 Chiller

Glen Dimplex Deutschland GmbH

Geschäftsbereich RIEDEL Kältetechnik

Am Goldenen Feld 18

D-95326 Kulmbach

Phone: +49 (0) 9221 / 709 555
Fax: +49 (0) 9221 / 709 549

HEADQUARTERS

GERMANY

Phone: +49 (0) 9221 / 709 545

Fax: +49 (0) 9221 / 709 529

e-mail: [email protected]

http://www.Riedel-Cooling.com

PARTS

SERVICE

HOTLINE

NORTH

AMERICA

Phone: ++1-877 RIEDEL1

Phone: ++1-877 -743 -3351

Fax: ++1-734 -595 -9829

e-mail: [email protected]

http://www.riedel-usa.com

Summary of Contents for P030

Page 1: ...Feld 18 D 95326 Kulmbach Phone 49 0 9221 709 555 Fax 49 0 9221 709 549 HEADQUARTERS GERMANY Phone 49 0 9221 709 545 Fax 49 0 9221 709 529 e mail service Riedel Cooling com http www Riedel Cooling com PARTS SERVICE HOTLINE NORTH AMERICA Phone 1 877 RIEDEL1 Phone 1 877 743 3351 Fax 1 734 595 9829 e mail service riedel usa com http www riedel usa com ...

Page 2: ...rt of this document may be reproduced processed copied or distributed by either conventional or electronic means without the prior written consent of Glen Dimplex Subject to errors and technical changes Glen Dimplex assumes no responsibility for any errors in this documentation To the extent permissibly by law Glen Dimplex will not be liable for any warranty claims for direct or indirect damages a...

Page 3: ...TECHNICAL DATA 17 3 1 HYDRAULIC DATA 17 3 2 ELECTRICAL DATA 17 3 3 GENERAL DATA 17 3 4 NAME PLATE 18 4 TRANSPORT AND STORAGE 19 4 1 TRANSPORT SPECIFICATION 19 4 2 TRANSPORT USING A FORKLIFT 20 4 3 TRANSPORT USING A LIFT TRUCK 21 4 4 TRANSPORT USING A CRANE 22 4 5 STORAGE OF THE P030 CHILLER 23 5 INSTALLATION 24 6 MOUNTING 25 6 1 CONNECTION OF WATER PIPING 25 6 2 ELECTRO TECHNICAL CONNECTION 26 6 3...

Page 4: ...12 1 REPLACING FILTER ELEMENT 37 13 PERIODICAL INSPECTIONS AND TESTS 38 14 MALFUNCTIONS TROUBLESHOOTING 40 14 1 MALFUNCTIONS TROUBLESHOOTING OF CONTROL AND OPERATING UNIT ST 181 40 15 OPTIONS 44 15 1 WATER CIRCUIT 44 15 2 ELECTRICAL SYSTEM 44 15 3 COOLING AIR SUPPLY 44 ...

Page 5: ...ents Part 3 Installation site and personal protection EN 378 4 2008 Refrigerating systems and heat pumps Safety and environmental requirements Part 4 Operation maintenance repair and recovery EN 60529 1991 A1 2000 Degrees of protection provided by enclosures IP EN 12100 2004 Parts 1 2 Safety of machinery Basic concepts general principles for design EN 13857 2008 Safety of machinery Safety distance...

Page 6: ...owing graphical symbols Danger Safety note pointing out an imminent danger Failure to heed the warning may result in serious bodily injury and even death Caution Safety note to indicate the presence of a potential hazard Failure to heed the safety notice may result in minor bodily injury Notice This symbol identifies important information or a useful tip concerning the application of the equipment...

Page 7: ...ectrical utility company have to be complied with Always disconnect the power supply before working on the P030 Chiller Caution Specific regional or national provisions applicable in the country where the unit will be installed must be adhered to The closed refrigeration circuit contains refrigerants and refrigeration oil These must be properly disposed of when performing service work or placing t...

Page 8: ...ded Drinking Water Properties Appearance clear no sediments Colour transparent Ingredients Unit Value Electric conductivity at 25 C µS cm 80 750 Hydrogen concentration at 20 C pH value 6 5 9 5 Chloride max mg l 250 Total hardness min dH 6 Total colony count at 22 C max CFU s ml 100 1 4 Handling of Refrigerants Notice When handling refrigerants all legal provisions and guidelines must be complied w...

Page 9: ... and the COO system separator Siemens Magnetic Resonance Tomograph must not exceed 30 to 10 meters 1 5 2 Operation The owner or operator of the P030 Chiller has the obligation to establish emergency practices in the case of accidents and malfunctions Based on this Operating Manual the operator must draw up a short version of the operating instructions quick reference guide and make it available to...

Page 10: ...l mixture ratio 60 40 for the system separator COO of the P030 Chiller The system separator supplies the connected components equipment to be cooled with cooling water maintaining its temperature at a constant level It may only be operated in conjunction with the specified devices Notice No changes are allowed to be made to the P030 Chiller The P030 Chiller must not be operated or used in conjunct...

Page 11: ...Translation of the Original ENGLISH FOR YOUR SAFETY 454522 68 07 01 E 11 27 06 2012 1 7 Declaration of Conformity ...

Page 12: ...and the fans 2 1 Overview P030 Chiller View of an open chiller 1 Pressure vessel 2 Fan 3 Condenser 4 Expansion tank 5 Evaporator 6 Compressor 7 Control cabinet 8 Control switch 9 Main switch 10 Vent 11 Pump 2 2 Refrigeration Circuit The refrigeration circuit is a closed loop system in which the refrigerant R134 circulates as the heat transfer medium The water heated by the system separator is reco...

Page 13: ...ing air by the condenser 2 in the form of waste heat by means of the two fans 3 The refrigerant is thus liquefied and passed to the inlet of the expansion valve 5 via the liquid receiver pipe expansion the filter drier 7 and the sight glass 6 The expansion valve permits liquid refrigerant to enter the evaporator as a function of the temperature Block flow diagram Refrigeration Circuit 1 Compressor...

Page 14: ...nd monitoring purposes The water circuit is provided with its own pump 2 4 Cooling Air Supply The heat transferred to the evaporator upon cooling the water as well as the heat generated by the compressor motors are absorbed by the refrigerant and given off to the cooling air in the condenser As cooling air the ambient air is used which is drawn through the condenser by the fans the air is warmed i...

Page 15: ... Each compressor is equipped with an overheat protection thermal contact Klixon In the event of an increase in motor current in conjunction with a rise in the winding temperature the overheat protection trips and the compressor is switched off The overheat protection resets itself automatically after the windings have cooled down This malfunction is not indicated on the control and operating unit ...

Page 16: ...l required components for the automatic switching controlling and regulating operation are contained in the control cabinet The main electric circuits are of a non fused design featuring motor protecting switches The water outlet temperature is kept constant by the control and operating unit at a given setpoint value by activation of power stages in the refrigeration circuit The current water outl...

Page 17: ... 3 K Operation volume flow cooling medium m 3 h 3 Max operating pressure against closed valve bar 3 8 at 50 Hz 5 4 at 60 Hz Max allowable pressure cooling medium circuit bar 10 3 2 Electrical Data Values Description Unit 50 Hz 60 Hz Operating voltage V Ph Hz 400 3 50 460 3 60 Power input overall system kW 28 34 Max current draw A 50 54 Fuse protection at site A max 63 max 63 3 3 General Data Descr...

Page 18: ...7 06 2012 3 4 Name Plate Name Plate 3 4 1 Installation Location of the Type Plate The name plate is attached to the front of the control cabinet at the bottom on the right Location of the name plate and the barcode identification label Barcode identification label Name plate ...

Page 19: ...n principle not permitted Damaged units must be sorted out immediately The in house transport is carried out by a forklift lift truck or crane The P030 Chiller must be deposited on a level surface to prevent any distortion of the base frame 4 1 Transport Specification Weight see Chapter Technical Data Main dimensions see Chapter Technical Data Ambient temperature range 20 C to 60 C at a rel ative ...

Page 20: ... a fork lift the recesses provided at the broadside of the base frame of the unit should exclusively be used Do not lift the unit until the forks have been inserted horizontally all the way beneath the unit symmetrically to the centre of gravity of the P030 Chiller Recesses Transport with Forklift Caution The lifting rate should be kept to a minimum ...

Page 21: ...ned Caution The lifting rate should be kept to a minimum Handling the unit from the broadside The forks of the lift truck must extend all the way through the unit the fork rollers must project from the other side of the unit Only then may the P030 Chiller be lifted exercise care to prevent the load from becoming off centred Caution The lifting rate should be kept to a minimum The P030 Chiller can ...

Page 22: ...s lifting chain assemblies according to DIN 5687 5688 Both load suspending devices comply with the requirement of a sling with equal rope or chain lengths to be used Rope inclination angle Ensure that the rope inclination angle as shown in the illustration is complied with Lifting rate Keep lifting rate to a minimum VLift 10m min precision lifting jerk free lifting operation Depositing the P030 Ch...

Page 23: ...upported on additional square beams in a dry room protected from frost Permissible storage temperature range 20 C to 60 C For storage in ambient temperatures below 0 C it i s imperative that decommissioning measures be taken See Chapter Decommissioning Caution It is on principle not allowed to stack the appliances Stacking may lead to serious accidents and damage to the units ...

Page 24: ...ration mountings are not required Any national or local installation and mounting regulations must be complied with For different installation conditions consult the manufacturer Notice To ensure trouble free operation of the P030 Chiller as well as to provide adequate access for the performance of maintenance and repair work minimum clearances must be maintained when installing the unit See also ...

Page 25: ...connection conditions all applicable technical data have to be submitted to Glen Dimplex Deutschland GmbH in order to obtain from them a written special approval prior to commissioning To avoid any damage the corrosion behaviour of the materials used in the equipment to be cooled with respect to the water must be taken into consideration see also the Chapter Commissioning Connection of Water Pipin...

Page 26: ...ate a jumper wire is inserted across the terminals The general fault indicator is wired to the terminal in the form of a potential free contact See also circuit diagram in the Appendix Close and lock the control cabinet door Engage and lock the panel assembly 6 3 Optical Fibre Connection Activities to be performed Open disengage and remove panel assembly on the operating side using the supplied ke...

Page 27: ...Translation of the Original ENGLISH MOUNTING 454522 68 07 01 E 27 27 06 2012 Installation instructions for optical fibre cable ...

Page 28: ...of 60 40 may be used The following materials may be installed in the water circuit of the P030 Chiller Copper Stainless steel Brass Red bronze Plastic Depending on the materials used in the chiller remote water circuit installation to be provided by the customer material incompatibilities could result in a corrosion hazard This must especially be taken into account where galvanised and aluminium m...

Page 29: ...device air bleeder 6 on the tank 5 is venting 05 After finishing the venting process open valve 2 and also K F E valve 4 06 After escaping only pure cooling medium without air bubbles out of K F E valve 4 close this valve and open ball valve 1 07 Fill the cooling circuit up to a pressure of about 1 7 to 2bar see pressure gauge 8 While you re doing this air bleeder 7 is venting 08 After venting is ...

Page 30: ... electrical connections in accordance with Chapters 6 2 and 6 3 Switch on the pump Observe the small display window in the rotation direction sensor The rotation direction is correct if a black area appears in the window no further activities are required In the event that a white area appears in the window the following steps must be performed Disconnect the P030 Chiller from the power supply pla...

Page 31: ...riod or if it is to be disassembled the unit has to be taken out of service The following procedure should be followed Control switch at the front of the unit in position 0 Main switch at the front of the unit in position 0 Switch off the power to the chiller Completely drain the water circuit including tank pump pipes and filters see flow diagram in the Appendix Notice Take freeze protection meas...

Page 32: ... 32 454522 68 07 01 E 27 06 2012 9 SHUTDOWN IN EMERGENCIES Danger The safety notices contained in Chapter 1 must be complied with Turn power disconnect switch main switch on the control cabinet of the P030 Chiller to the OFF position 0 Main switch in 0 position ...

Page 33: ...ioning the environment relevant requirements regarding recovery reuse and disposal of fuels oils and components according to DIN EN 378 are to be complied with Notice The operator of the P030 Chiller is responsible for the proper disposal of used fuels oils and system components The disposal of the water containing additives is to be effected in agreement with the competent local authorities ...

Page 34: ...tection signal 11 1 Control and Operating Unit ST 181 No Function No Function 1 Display 7 SET call up of setpoint S1 compressor control S2 not used 2 Alarm status displays General fault alarm Temperature alarm Low water level Pump Refrigeration fault High pressure HP Low pressure LP 9 HP LP button Reading of HP sensor HP LP button pressed Reading of LP sensor HP LP DOWN button pressed 3 Control mo...

Page 35: ...OL AND OPERATING UNIT 454522 68 07 01 E 35 27 06 2012 In the normal state the flow temperature of the water circuit is indicated on the display Setpoint adjustment The setpoint is adjusted by simultaneously pressing the SET button and the UP or DOWN button ...

Page 36: ...priate know how Component to be serviced Interval Activity P030 Chiller in general 2 weeks Visual inspection of the air filter element for contamina tion Visual inspection of refrigeration circuit for leaks In the case of oil leaks call customer service Phone 49 0 9221 709 545 Fax 49 0 9221 709 529 Water circuit cooling water 2 weeks Visual inspection of the water circuit for leaks Check water lev...

Page 37: ...e lower edge of the protective grille until it can be removed from the magnetic fixing points Disengage the protective grille at the top Remove the filter element fixed in place by velcro fastener The installation of a new filter element is performed in the reverse order of sequence View of the chiller from the left as well as a detailed view with protective grille and filter element removed ...

Page 38: ...nel in accordance with EN13313 or a specialist enterprise in compliance with environmental requirements with respect to the reuse and disposal of fuels oils and component parts Definition of Test Designations M1 Inspections tests must be carried out following any intervention in the refrigeration circuit due to required repair or service activities replacement of components elimination of leaks re...

Page 39: ... for oil leaks in the area of the compressor and condenser connecting lines suction line pressure line Inspection of the condenser heat exchanger surface and the refrigerant piping for corrosion damage Inspection of the mounting and attachment of all piping and components for security Visual inspection of the water circuits under operating conditions for leaks Check that the operating manual is av...

Page 40: ...play Malfunction Cause Remedy F1 Motor fault pump Motor protecting switch has tripped Pump motor overloading due to mechanical sluggishness Check pump replace if necessary Place motor protecting switch in position 1 Motor fault compressor Motor protecting switch has tripped Compressor motor overloading due to mechanical sluggishness Check compressor replace if necessary Place motor protecting swit...

Page 41: ... manually so that the P030 Chiller can be restarted The compressors and fans will be enabled after a delay of 180 seconds Fault due to high pressure limiter Sensor has tripped Cooling air temperature too high Ensure proper heat dissipation by increased air changes at the installation site Fans fail to rotate Check fans for proper operation Condenser or filter element dirty Clean condenser with com...

Page 42: ...d by qualified personnel Permanent formation of bubbles in sight glass Call customer service F6 After the cause of the low pressure fault has been eliminated the alarm is automatically reset The compressors and fans are enabled after a delay of 180 sec Low pressure limiter Sensor has tripped Refrigerant shortage due to leaks in refrigeration circuit Refrigerant shortage Expansion valve defective T...

Page 43: ...ed Water temperature too high Allow water to cool or replace sensor correct reset any additional malfunctions that may be signalled F13 Sensor F4 Temperature alarm Temperature limit values exceeded Water temperature too low Increase water temperature correct reset any additional malfunctions that may be signalled F19 Sensor F2 Broken sensor or short circuit Defective sensor Check sensor replace if...

Page 44: ... for temperature stabilisation of the control cabinet inside temperature versus the ambient temperature condensation water formation and for the purpose of ensuring minimum temperatures for the switchgear and controlgear inside the control cabinet Outdoor installation and pump shutdown upon a general fault alarm In the event of a general fault alarm the pump is shut down by the controller After th...

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