OPERATING MANUAL - Keith Industrial Group

1 ENGLISHOPERATING MANUALL 0/5 TR2 Glen Dimplex Deutschland GmbHGeschaftsberelch RIEDEL KaltetechnikAm Goldenen Feld 18D-9532G KulmbachPhone: +49 (0) 92 21 / 709 555 Fax: +49 (0) 92 21 / 709 549e-mail: document was drawn up by the Technical DocumentationDept. of Glen Dimplex reserves all rights to this documentation, especiallythe right to reproduce, distribute and translate this document. Thisalso applies in case of patent and Industrial rights applications. Nopart of this document may be reproduced, processed, copied ordistributed by either conventional or electronic means without theprior written consent of Glen Dimplex. Subject to errors andtechnical Dimplex assumes no responsibility for any errors in thisdocumentation. To the extent permissibly by law, Glen Dimplex willnot be liable for any warranty claims for direct or indirect damagesarising in connection with the supply or non-use of this Anwender einzutragenTo be entered by the user ;A remplir par I'utilisateur:Da completare da parte dell'utenteDatos a cumplimentar por el usuarionInventarnummer:Inventory number:No.

2 D'inventaireNo. d'inventarioN de inventarioAufstellungsort:Installation site:Lieu d'implantationLuogo di installazioneLugar de OF CONTENTS1. For Your SafetyDescription of the Process CoolerTechnical DataHandling and StorageInstallationMounting7. Commissioning8. Decommissioning9. Shutdown in Emergencies10. Environmental Requirements11. Operation12. Maintenance13. Periodic Inspections14. Malfunctions/Troubleshooting15. Technical Signs and Signs and Handling of Safety Purpose of the Process Refrigeration Water Safety and Monitoring Electrical / Control Handling Handling By Handling By Lift Handling By Storage of the Process Indoor Connection of Water Electrotechnical Temperature Parameter Flow Spare Parts Pump Sample System Sample Quick Reference GuideCircuit DiagramParameter GBENGLISH1, FOR YOUR RegulationsThe design, construction and development of the process cooler arein compliance with the following national and Directives / Standards- EC Machinery Directive 2006/42/EEC- EC EMC Directive 2004/108/EEC- EC Pressure Equipment Directive 97/23/EEC-EN378T1AT2/T3n~4- EN 60529-EN IS012000-1.

3 -2-EN ISO 13857- EN 349- EN 60204-1-EN 61000-6-2-EN 61000-6-4 national Directives-BGR500 Refrigeration plants and heat pumpsDegrees of protection provided byenclosures (IP)Safety of machinerySafety of machinerySafety of machineryElektrische Ausrustung von MaschinenElectromagnetic compatibility -generic emission standard for industrialenvironmentElectromagnetic compatibility -generic immunity standard for industrialenvironmentAccident prevention regulations concerningrefrigeration plants and heat pumpsENGLISH'mutt* Signs and SymbolsThroughout this OPERATING MANUAL , the information and notices beioware identified by graphical symbols:Danger!Safety note pointing out an imminent danger. Failure to heed thewarning may result in serious bodily injury and even !Safety note to indicate the presence of a potential hazard. Failure toheed the safety notice may result in minor bodily injury or damage too \e !This symbol identifies important information or a useful tipconcerning the application of the ProcedureThis symbol identifies a work Safety NoticesForthe installation, operation and maintenance of the processcooler, the following regulations and safety notices have to beobserved:Any work on the process cooler may only be performed byqualified personnelAll relevant accident prevention regulations have to beobservedDo not allow anybody to stand or pass underneath the forkswhen lifting and setting down the process cooler; stay clear ofthe danger process cooler must be properly secured in order toprevent it from tipping overThe safety devices must not be deactivatedThe electrotechnical connections of the process cooler as wellas all servicing and repair work must be performed accordingto and conforming with all relevant VDE, EN and IECstandards.

4 Beyond that, the technical connectionrequirements of the local electrical utility company have to beobservedThe process cooler must always be disconnected from thepower source before performing any service work on itSpecific regional or national provisions applicable in thecountry where the unit will be installed must be adhered toThe closed refrigeration circuit contains refrigerants andrefrigeration oil. These must be properly disposed of whenperforming service work or placing the unit out of service(environment)The cooling water additives have a caustic effect on skin andeyes. When working with cooling water additives, eyeprotection devices and gloves must be worn. Follow thedirections on the product's labelAnyone working on the refrigeration circuit must be protectedby personal protective equipmentThe process cooler is to be used exclusively for the cooling ofwater in accordance with TRUMPF specificationsWatch out for any incompatibilities of materials in the entirewater For Your SafetyENGLISHri*rif tin Handling of RefrigerantsWhen handling refrigerants it is imperative that the relevant statutoryregulations and guidelines be complied with.

5 Only adequately skilledpersonnel may carry out this kind of proper disposal of refrigerants and parts of the system that are nolonger serviceable lies within the responsibility of the operator of theprocess Safety Requirementsconcerning the operation of refrigeration systems within theEuropean UnionThe following information applies to refrigeration systems with closedrefrigeration circuits that are operated within the European Union. Insome member states additional requirements may apply, forreasons relating to environmental are incorporated in the refrigeration systems whoseworking pressures are subject to the regulations laid down in thePressure Equipment Directive 97/23/EEC and European standardEN 378 (Parts 1 - 4, edition September 2000).Apart from the requirements relating to the design, equipment andtesting of the process coolers prior to delivery, also the operator ofsuch systems has to comply with requirements imposed bystandard EN 378 and any additional regulations that may concern the installation, the operation and the periodicinspections of process InstallationWith regard to the installation of refrigeration systems in spacesbelow ground level or on upper floors of a building without anadequate number of emergency exits, the requirements of EN 378with regard to the installation site and the protection of people are tobe complied regard to the refrigerant charge inside this process cooler, aminimum room volume of7m3must be ensures that any sudden refrigerant loss (leakage)

6 In the caseof damage to the unit and the resulting oxygen displacement will notpose any risk to the health of persons that may be present in fi49 ENGLISH tillIH 11 <*a u i1, OperationThe owner or the operator of the process cooler is obligated toestablish emergency practices (in the case of accidents andmalfunctions). A short version of the OPERATING instructions must bedrawn up by the operator-based on this present OPERATING MANUAL -which shall be made known to his quick reference sheet must be posted in the immediatevicinity of the process cooler and must be clearly sample on page 37 The owner or operator is obligated to maintain a system log for theprocess system log shall either be kept on site near the process cooler,or in the event that the data are stored in a computer of the owner oroperator, a printout of the log must be kept in the vicinity of theprocess cooler. It must be ensured that these data are accessible tocompetent persons forthe performance of repairs and sample on page Periodic InspectionsTo ensure compliance with minimum safety and health requirementsas set forth in standard EN 378, periodic tests {regular inspections)of the process cooler have to be carried out by competent operator is responsible forthe performance of these regularinspections.}

7 (See Chapter 13 Periodic Inspections). Purpose of the Process CoolerThe process cooler described in this MANUAL is designed exclusivelyfor the cooling of aTRUMPF machine and features one water Pnr Your SafetVENGLISH ttttiiitm it it-lit*I2. DESCRIPTION OF PROCESS COOLERThe process cooler is a cooling plant ready for plug-in, comprising arefrigeration and water circuit including all fittings and regulating/control equipment required for automatic process cooler is designed for the cooling of water in atemperature range from +15 C to +35 heat extracted from the water is given off to the surrounding airvia the refrigeration circuit through action of the *M tlgf *ft Refrigeration CircuitThe refrigeration circuit is a closed system in which the refrigerantcirculates as the working water heated by the machine to be cooled is recooled in theevaporator (5). The liquid refrigerant is thereby passed through thepiping in a counter-flow arrangement with respect to the water.

8 Therefrigerant evaporates as it takes up the waste heat from themachine's cooling vaporized refrigerant is drawn in by the compressor {1) and thencompressed (rise in pressure and temperature). The refrigerant alsoabsorbs the heat of the compressor motor; this heat is given off tothe surrounding air in the form of waste heat by the condenser {2}by means of the fan (3).The refrigerant is thus liquefied and is passed to the inlet of theexpansion valve (4) via the liquid receiver and the filter drier (11). Theexpansion valve permits liquid refrigerant to enter the evaporator asa function of the cycle is now refrigeration performance is controlled by the cycling on and offof the compressor.(See P&l Flow Diagram)2,2 Water CircuitThe water circuit with its integrated tank (35) is designed as asystem open to the constancy of the water outlet temperature is influenced by thewater volume inside the tank (35). The pump (30) conveys the waterout of the tankto the TRUMPF machine, then through theevaporator (5) and back to the tank.}

9 (See P&l Flow Diagram)of the Process CoolerENGLISH tttitnitm i* Safety and Monitoring Safety DeviceHigh-Pressure Control (HP)The high-pressure control is designed to protect the process cooleragainst an extremely high OPERATING pressure in the the event of a malfunction, the HP control switches the processcooler off, and the malfunction is signalled to the control panel (F4).Restarting the process cooler is not possible until the pressure hasdropped to the preset pressure difference and the reset button on thepressostat has been ,2 Monitoring DevicesLow Pressure Control (LP)The low-pressure control protects the process cooler againstextremely iow OPERATING pressure in the refrigeration circuit. In theevent of a malfunction, the control switches off the process coolerand signals the malfunction to the control panel (F5).Restarting of the process cooler is effected automatically as soon asthe pressure has risen by the preset pressure Starting AidThe winter starting aid is designed to prevent any low pressuremalfunctions in low ambient temperatures during the start-up phaseof the cooling operation until normal OPERATING conditions have Overheating ProtectionThe compressor is equipped with an internal Klixon (overheatprotector).

10 In the event of an increase in motor current in conjunctionwith a rise in winding temperature, the Klixon will trip causing thecompressor to be switched off. The Klixon is reset automaticallyafter the windings have cooled Contact - Fan MotorIn the event of an increase in motor current in conjunction with anincrease in winding temperature, cooling operation is switched off bythe thermal malfunction is indicated at the control panel (F4).Air Filter MonitorThe max. permissible contamination level of the air filter element ismonitored via the condensation pressure. If the max. permissiblepressure is exceeded, a "Filter contaminated (F6)" warning messageis displayed on the control fU9 RR m 1^ENGLISHF loat SwitchThe float switch monitors the water level in the the minimum water level ensures that the water outlettemperature remains the event of a water shortage, the pump will be switched off. Thewater shortage will be indicated at the control panel (F3).