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Troubleshooting

52

11 Troubleshooting

11.1 Notes

The following must be observed in order to avoid injuries and damage to property:
•

Only qualified personnel are authorised to perform these tasks.

•

Comply with the information given in the "Safety" section.

DANGER

Risk of injury caused by electric current!

When the device is open, parts of the device may be energised and cause an
electric shock when they are touched.
The following points must be observed when performing work on the open unit:
•

Comply with the information that is given in the "Safety" chapter.

•

Only suitably qualified persons are authorised to perform these tasks.

1.

Disconnect the unit from the power supply in order to deenergise it.

2.

Secure the unit so that it cannot be switched on again accidentally.

3.

Check whether the unit is properly disconnected from power and
absolutely voltage-free.

4.

Earth and short-circuit the unit.

5.

Cover any adjacent live parts and secure the danger area.

WARNING

Carry out instructed work only!

There is an increased risk of injury to persons who perform tasks for which they
are not suitably qualified or trained.
Troubleshooting shall only be carried out by qualified personnel. Contact the
after-sales service particularly in the event of malfunctions in the electrical
system or the refrigeration unit (if provided).

Содержание termotek P70100-24495

Страница 1: ...Instruction Manual ORIGINAL INSTRUCTION MANUAL Cooler P70100 24495 90000899992 00 EN 2019 07 02 ...

Страница 2: ...l as any reproduction and distribution are prohibited without our prior consent The main components devices arrangements software as well as the control and instrumentation equipment on all of our products are protected both at home and abroad by patent applications patents utility models or copyrights Copyright by termotek GmbH Im Rollfeld 6 D 76532 Baden Baden Federal Republic of Germany termote...

Страница 3: ...llation start up 18 4 5 Operation 19 4 6 Maintenance 19 4 7 Operating faults 19 4 8 Residual risks 20 4 9 Use of chemicals 20 4 10 Use of cleaning agents 21 4 11 Safety labels 22 5 Description Overview 23 5 1 General information 23 5 2 Safety devices 24 5 3 Factory protective measures 24 5 4 Deactivation 24 5 5 Foreseeable misuse 25 6 System Layout 26 6 1 Overview 26 6 2 Information concerning the...

Страница 4: ...dium Refilling the cooler with medium 48 10 4 Filter replacement 49 10 5 Refrigeration unit 50 10 5 1 General information 50 10 5 2 Refrigerant sight glass 51 10 6 Restart 51 11 Troubleshooting 52 11 1 Notes 52 11 2 General malfunctions 53 11 3 Electrical connection 54 11 4 Refrigeration unit 54 11 4 1 Refrigerant sight glass 55 11 5 Unit specific 56 11 6 Restart 56 12 Disconnecting the device 57 ...

Страница 5: ...echnotrans co uk England technotrans france sarl ZAET Les Haies Rue Albert Einstein 60740 Saint Maximin cedex Phone 33 0 3 44 24 2128 Fax 33 0 3 44 24 85 26 Email service france technotrans fr France technotrans France SARL Surcusal en ESPAÑA Paseo de Recoletos 7 y 9 5a 28004 Madrid Phone 34 91 679 2119 Email service spain technotrans es Spain technotrans italia s r l Via Spallanzani 18 20025 Legn...

Страница 6: ... 1566 Email service singapore technotrans com Singapore technotrans india pvt ltd 24 Eden Plaza Second Floor Mount Poonamallee High Road Nandambakkam Chennai 600 089 Tamil Nadu Phone 91 0 44 4351 9349 Email service india technotrans com Chennai India technotrans group taicang co ltd No 8 North Loujiang Road Taicang 215400 P R China Phone 86 0 512 5367 8100 Fax 86 0 512 5367 8199 China Australia te...

Страница 7: ...unit when contacting us e g for spare part orders warranty claims etc Product name Serial no NOTE If necessary enter the information which is stated on the type plate of the unit into the table Name of the unit Product Name Serial number Serial No Part number Part No Year of manufacture Year of Manufacture ...

Страница 8: ... Keep the instruction manual in a place where it is readily accessible at all times It must be complete remain with the machine and must be available to all authorised persons Maintain the instruction manual in a clearly legible state at all times Hand over the instruction manual along with the device if it is resold The unit system may present unavoidable residual risks to persons and property Th...

Страница 9: ...assembly and removal Qualified personnel mechanics Mechanical work during start up elimination of faults and malfunctions maintenance and shut down Training as an industrial mechanic or an equivalent professional qualification Start up maintenance elimination of faults and malfunctions shut down disassembly and removal Qualified personnel trained electricians Electrical work Specialised electrical...

Страница 10: ...tion of danger The signal word WARNING identifies a potential danger Any non adherence may result in severe injuries or death CAUTION Short description of danger The signal word CAUTION identifies a potential danger Non compliance may result in minor to medium injuries NOTICE Short description The signal word NOTICE identifies a potential risk of damage to property Non compliance may cause damage ...

Страница 11: ...ertification of instruction manuals under ecological points of view It is listed under the green safety instruction With the ecoDoc seal of quality the manufacturer indicates that the product documentation includes notes concerning the potential ecological hazards resulting from operating errors or other tasks that are performed with or on the product Companies thereby make a contribution to the p...

Страница 12: ...ted parts and annexes Unauthorised structural or technical modifications of the unit system Use of untrained personnel Use of the unit system with defective or improperly installed safety devices and guards Operating errors Failure to maintain the unit system Non elimination of faults malfunctions Use of non authorised spare parts Other misuse Catastrophic events caused by foreign objects or force...

Страница 13: ...nly use spare parts approved by the after sales service No warranty claim The use of media e g washing agents additives cleaning agents etc that are not approved may result in damage to the unit or system The warranty will be rendered void The same shall apply when different media are mixed Use only media that have been approved by the manufacturer NOTE Removing type plates will make the warranty ...

Страница 14: ...and maintain appropriate measures such as installing firewalls using authentication data encryption installing anti virus programs etc to protect the device the network its systems and the interface from any interference The operating company must undertake to protect the device from vulnerabilities prevent unauthorised access faults intrusion loss and or theft of data or information technotrans S...

Страница 15: ... and is in compliance with the recognised safety regulations and standards The unit system is safe to operate Non compliance with the instructions and safety notes in this instruction manual may lead to substantial hazards to persons and damage to the unit system Only use specialised personnel who are familiar with the fundamental health and safety rules and regulations and who have been briefed a...

Страница 16: ...e measures for the safe operation have been coordinated or implemented in consultation with the manufacturer or other competent authorities 4 3 Safety of personnel Knowledge of and compliance with the present content is a prerequisite for the protection of persons against danger and for the avoidance of errors and mistakes Tasks e g maintenance and service tasks should be performed only by suitabl...

Страница 17: ...equipment may cause serious injuries or death Wear the prescribed personal protective equipment e g hearing protection eye protection safety shoes helmet protective clothing safety gloves and respiratory protective equipment Long hair must be tied back Do not wear any jewellery or loose fitting clothes There is a risk of injury if these items get caught in or are pulled into any moving parts of th...

Страница 18: ... equipment load handling attachments and lifting accessories and ensure that they are in a perfect technical state and have a sufficient load bearing capacity Take the attachment points and centre of gravity of the load into consideration Do not add any additional attachment points to the units systems by welding flame cutting or drilling There is a risk of cracking due to the notch effect of the ...

Страница 19: ...place at and around the unit system by issuing corresponding instructions and performing checks Observe the controls and indicators during operation 4 6 Maintenance The operator must ensure that the unit system and its safety devices and guards are kept in a functional state The control devices as well as the safety devices and guards must be checked in terms of their effectiveness Only specialise...

Страница 20: ...are aggressive to the components Observe the relevant material safety data sheets of the suppliers Note concerning the protection of the environment The improper disposal of chemicals e g additives has a negative impact on the environment Chemicals must not be disposed of as household waste and it must be ensured that they are not released into the sewage system or soil Wear suitable protective eq...

Страница 21: ...r Do not use any cleaning agents containing silicone or chlorine unless explicitly specified by the manufacturer In case of doubt the user should perform a test to see whether the detergents chemicals are compatible with the materials used The materials used for this product have been selected on the basis of several years of field experience of these products worldwide If the product is used as i...

Страница 22: ...cal systems Carelessness can lead to electrocution Observe the Safety section Wear protective clothing Warning electrical hazard Do not connect or disconnect any of the electrical connectors under voltage load Warning The unit contains a liquid under pressure rotating parts and high voltage Do not use the unit if the panels have been removed Disconnect the unit from the power supply prior to openi...

Страница 23: ...n max temperature switch the unit off immediately Non compliance may lead to consequential damage to the overall system termotek GmbH shall assume no liability for such consequential damage The following requirements must be met for the operation of the unit Use the unit solely inside buildings An operation in the open air is not allowed Use the unit solely with a fixed fan grid Ensure a free suct...

Страница 24: ... high pressure The high pressure switch is automatically reset after the triggering 5 3 Factory protective measures Warning labels in accordance with the German regulation BGV A8 e g Warning dangerous voltage Protective earthing potential equalization for static discharge 5 4 Deactivation The device is de energized by disconnecting the electrical connecting line The unit is switched on and off via...

Страница 25: ...Set up in unsuitable locations Transport with filled tank Stepping on the unit Outdoor use Operation of the unit without medium Operation in hazardous areas with a risk of explosion Operation with missing or damaged sub assemblies intended to protect the safety of persons and the device system Operation of the unit without unit cladding Use of chilling media that are not specified and approved in ...

Страница 26: ...System Layout 26 6 System Layout 6 1 Overview Fig 2 Cooling unit 15591 IN1 IN3 IN2 OUT1 OUT2 OUT3 6 7 8 Wi E IN4 OUT4 18 17 16 15 10 12 13 14 1 2 3 4 5 9 11 ...

Страница 27: ...ndenser Temperature sensor Refrigerant collector Filter dryer Refrigerant sight glass Expansion valve Solenoid valve 11 Air filter 12 Castors with brakes 13 Fill level indicator tank 14 Switch box with Power supply unit Automatic circuit breaker Air break contactor Circuit board with fuses 15 Pump 16 Control valve 17 Filter 18 Tank with Fill level indicator Float switch Venting system Connection p...

Страница 28: ...ate of the device The refrigerant is classified in safety group A1 in accordance with EN 378 Refrigeration systems and heat pumps CAUTION Improper handling of the refrigeration unit Danger due to improper handling of the refrigeration unit The unit should be serviced and repaired only by persons who have been trained in the use and maintenance of the unit and are informed about the potential hazar...

Страница 29: ...on NOTE The pressure vessels of the refrigeration system are subject to periodic inspections depending on the device category and in accordance with the Pressure Equipment Directive Pressure vessels of category 1 and 2 must be tested by a competent person Pressure vessels of a higher category than category 2 must be tested by an approved inspection body e g TÜV in Germany The device category in ac...

Страница 30: ...ntities of fluorinated greenhouse gases added during installation maintenance or servicing or due to leakage whether the quantities of installed fluorinated greenhouse gases have been recycled or reclaimed including the name and address of the recycling or reclamation facility and where applicable the certificate number the quantity of fluorinated greenhouse gases recovered the identity of the und...

Страница 31: ...ge has occurred observe the following points Inform the forwarding agent and the supplier in written form Keep the packaging material Note down any external and internal damage Document the damage e g by means of photos Remove any transport material and packaging Note concerning the protection of the environment The improper disposal of packaging materials has a negative impact on the environment ...

Страница 32: ...e to follow signs if attached at unit when transporting unit Transport units with suitable lifting gear only Transport the unit only when it is empty Transport on suitable and secured transporting pallet When moving the unit the respective transport vehicle e g forklift pallet truck must be operated compliant with the local rules and regulations and according to relevant industrial accident preven...

Страница 33: ...icient space for operating maintaining and cleaning If provided keep the vents for incoming and outgoing air clear Observe relevant technical and building regulations Hoses and electrical cables must be laid such that there is no danger of tripping and that they are protected from damage When selecting an installation site the applicable safety regulations and manufacturer s instructions concernin...

Страница 34: ...hat are stated in the chapter Transport Location selection WARNING Risk of injury There is an increased risk of injury when working on the machine Observe the Safety section Start up maintenance and repair work should be performed only by trained and specialised personnel Ensure that the machine is at a complete standstill and secured against inadvertent start up prior to working on it Comply with...

Страница 35: ...cation Take the following measures prior to the set up Prepare the set up location level ground with a sufficient load bearing capacity Perform the set up in accordance with the specifications in the project drawings e g floor plan foundation plan if provided Set the unit up at the intended installation site Set up the unit in a horizontal position NOTE Use the unit only inside buildings Do not se...

Страница 36: ...ease observe the connection sizes in the Technical Data section in the appendix NOTE Please observe the direction of flow when installing the connecting pipes Fig 3 Medium connections general NOTE The hoses can be connected to or disconnected from the device connectors by pressing the locking device 1 The locking devices can be located on the hose or on the device itself For devices with plug type...

Страница 37: ...t A customer provided process water supply can be connected to the unit to dissipate the waste heat produced by the unit Connect the unit Process water inlet IN feed flow Process water outlet OUT return flow NOTE When a customer provided process water supply is connected to the unit the fans inside the unit become active ...

Страница 38: ...E Loose bolts and terminal clamping points During transport and installation screws and terminal clamping points might get loose Check all screws and terminal clamping points in the control cabinet for secure fitting prior to setting up the unit NOTICE Impairment of the unit operation EMC disturbance may affect the unit function negatively and or damage components in case of insufficient equipoten...

Страница 39: ... the unit when it is not or only insufficiently filled NOTE Information concerning the optimum medium quality can be found in the Technical data section Fig 4 Tank example 1 Alarm LED Illuminated Maximum tank fill level the functions of the unit will be switched off 2 Warning LED Illuminated Minimum tank fill level 3 Pilot LED Illuminated Tank overfilled 4 Pushbutton for switching the unit functio...

Страница 40: ... warning LED 2 light up since there is no medium in the tank 1 Connect a customer provided hose to the filling connector Wi to fill the tank 2 Fill the tank with the medium in accordance with the Technical data section via the filling connector Wi until the LEDs 1 and 2 go out 3 Check the fill level by way of the fill level indicator 5 4 Switch the unit on briefly To do so press the pushbutton 4 5...

Страница 41: ...comply with the following if applicable Ensure that any safety devices guards and covers which were removed prior to commencing the tasks have been properly reinstalled Ensure that the area around the unit system is free from tools materials or other pieces of equipment that had to be used Clean the workspace and remove any liquid spills or similar substances Check whether the safety devices and g...

Страница 42: ...ide panels are removed Open the side panels only in order to perform maintenance tasks and only in compliance with the safety instructions NOTICE Risk of damage to the components There is a risk of damage to the electrical components when electrical connectors are connected or disconnected under voltage load Do not connect or disconnect any of the electrical connectors under voltage load NOTICE Ri...

Страница 43: ...llowing symbols identify the operating states Switched on Switched off 9 3 Adjustments 1 Check the tank level If the fill level is too low top the tank up via the filler neck Compliance with the instruction provided in the Start up Filling section is mandatory 2 Switch the unit on by pressing the pushbutton The pushbutton illuminates 3 To stop the cooling process press the pushbutton again 9 4 Ref...

Страница 44: ... persons are authorised to perform these tasks 1 Disconnect the unit from the power supply in order to deenergise it 2 Secure the unit so that it cannot be switched on again accidentally 3 Check whether the unit is properly disconnected from power and absolutely voltage free 4 Earth and short circuit the unit 5 Cover any adjacent live parts and secure the danger area WARNING Health hazard The use ...

Страница 45: ...otection when performing disposal tasks Chemicals must be disposed of separately e g as special waste if applicable and supplied separately to the recycling centres Comply with the safety data sheets and also with the applicable national and local rules and regulations Note concerning the protection of the environment The improper disposal of consumables e g filters filter mats has a negative impa...

Страница 46: ... Replace them if necessary Screw fittings Check for tight fit Retighten if necessary Screw locking device Labels and symbols Check that the labels and symbols on the unit are complete and legible Missing or illegible labels symbols must be replaced Air filter Check for soiling and clean it if necessary Protective goggles respiratory equipment compressed air Refrigerant sight glass Check the moistu...

Страница 47: ...cal rules and regulations e g F gases regulation The following types of refrigeration units must be inspected for leaks Refrigeration units with a refrigerant filling quantity of more than five tonnes 5 t of CO2 equivalent Refrigeration units hermetically sealed systems with a refrigerant filling quantity of more than 10 tonnes 10 t of CO2 equivalent Certified and specialised personnel Contact the...

Страница 48: ... of damage to the components There is a risk of damage to the components if compressed air pressure higher than 1 bar 14 5 psi is used to blow out the device Blow the liquid into the tank with compressed air pressure below 1 bar 14 5 psi via the medium connections inlet outlet and drain it off via the drain e g by way of a draining hose or via a draining connector When blowing in the compressed ai...

Страница 49: ...ing the filter cup NOTE Liquid will escape when the filter cup 1 is removed Keep a collecting vessel ready and collect any escaping liquid 5 Lay bare the inline filter 2 6 Remove the clogged filter element and ensure its environmentally friendly disposal in accordance with the national and local regulations 7 Insert a new filter element 8 Clean the dismounted filter cup 1 9 Check the sealing ring ...

Страница 50: ... fins of the condenser used on air cooled versions NOTE In the event of any problems please consult a refrigeration specialist In the case of an air cooled condenser clean the cooling fins with the aid of compressed air or use a vacuum cleaner Do not damage the cooling fins Note concerning the protection of the environment Refrigerants are harmful to the environment if released into the atmosphere...

Страница 51: ...h cases a refrigerant specialist should be consulted 10 6 Restart Prior to using the unit system it must be absolutely ensured that there are no safety critical defects or malfunctions After the completion of the tasks and prior to switching the unit system on comply with the following if applicable Ensure that any safety devices guards and covers which were removed prior to commencing the tasks h...

Страница 52: ...nly suitably qualified persons are authorised to perform these tasks 1 Disconnect the unit from the power supply in order to deenergise it 2 Secure the unit so that it cannot be switched on again accidentally 3 Check whether the unit is properly disconnected from power and absolutely voltage free 4 Earth and short circuit the unit 5 Cover any adjacent live parts and secure the danger area WARNING ...

Страница 53: ... when the unit is switched on Keep housing closed during operation Never reach into the device when it is switched on Prior to opening the housing ensure that the device is off and secured against reactivation NOTE Re activation is permitted only after a thorough inspection of the cause of the error and after the device has been tested 11 2 General malfunctions Fault Cause Note No flow The connect...

Страница 54: ... due to improper handling of the refrigeration unit The unit should be serviced and repaired only by persons who have been trained in the use and maintenance of the unit and are informed about the potential hazards Risk of burns Do not touch the refrigerant hot gas pipes Risk of injuries Do not touch the sharp cooling fins of the condenser used on air cooled versions Note concerning the protection...

Страница 55: ... necessary Entry exit of cooling air obstructed Remove any objects from in front of or on top of the unit Insufficient external suction Check 11 4 1 Refrigerant sight glass Fig 8 Refrigerant sight glass example 1 Sight glass 2 Indicator The colour of the indicator indicates the moisture content of the refrigerant Green No moisture in the refrigerant Yellow Moisture in the coolant Replace the filte...

Страница 56: ...ervice department Frequent lack of water System leaks Check seal leaks Check safety valve for leaks 11 6 Restart Prior to using the unit system it must be absolutely ensured that there are no safety critical defects or malfunctions After the completion of the tasks and prior to switching the unit system on comply with the following if applicable Ensure that any safety devices guards and covers whi...

Страница 57: ...r through electric current Carelessness can lead to electrocution Disconnect the electricity supply before disconnecting the unit CAUTION Danger due to improper work practices Danger due to improper handling of the refrigeration unit The refrigeration unit may only be disconnected by specialist refrigeration companies Note concerning the protection of the environment Improper disposal places a bur...

Страница 58: ...r shutdown Pressurised systems present increased dangers Depressurise all of the circuits prior to dismantling the system or device The following steps must be performed 1 Disconnect all of the electrical connections leading to the system or unit 2 Disconnect the medium connections e g water connections 3 Remove all of the hose connections leading to the system or unit 4 Depressurise the circuit I...

Страница 59: ...cally and must not be thrown The device must only be stored vertically Ensure that the ambient conditions are in line with the Technical data Use suitable packaging material e g shock absorbing and vibration absorbing material preferably use the original packaging material Ensure that the packaging will protect the unit against dust and dirt Pack the unit so that it is protected against shocks and...

Страница 60: ...that they are not released into the sewage system or soil Wear suitable protective equipment gloves eye protection when performing disposal tasks Chemicals must be disposed of separately e g as special waste if applicable and supplied separately to the recycling centres Comply with the safety data sheets and also with the applicable national and local rules and regulations The components of the sy...

Страница 61: ...echnical data and further information 61 13 Technical data and further information NOTE Information about the technical data spare parts and conformity of the devices are prepared and provided separately ...

Страница 62: ... Installation site 29 33 Intended use 16 L Liability 12 M Maintenance 19 44 Maintenance schedule 46 Maintenance repair and overhaul 19 Making contact 7 Malfunctions 51 55 Manufacturer s address 5 Medium connections 36 N Notes 31 34 42 44 52 57 O Obligation to maintain records 30 Operating faults 19 52 Operating personnel 16 Operation 19 42 Overview 26 P Packing material 31 R Recycling 60 Refilling...

Страница 63: ...Index 63 T Target audience 9 Technical data 61 Transport 18 31 59 Transport material 31 Transport to the installation location 32 Type plates 13 U Unit specific 56 Use and storage 8 W Warranty 12 13 ...

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