Summary of Contents for technotrans termotek P70100-24495
- Page 1 Instruction Manual ORIGINAL INSTRUCTION MANUAL Cooler P70100-24495 90000899992-00 - EN 2019-07-02...
- Page 2 Copyright clause We reserve the right to implement technical changes which may result in deviations from the illustrations and information contained in this manual. The translation, disclosure to third parties as well 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,...
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Page 3: Table Of Contents
Contact Addresses..........................5 Manufacturer's address ........................5 Service addresses ..........................5 Making contact........................... 7 About this manual ..........................8 Use and storage ..........................8 Target audience ..........................9 Explanation of the various notes ..................... 10 Seal of quality ..........................11 Liability and warranty ..........................12 General information ......................... - Page 4 Setting Up..............................34 Notes..............................34 Installation............................35 Medium connections........................36 Electrical connection........................38 Filling..............................39 Final steps after start-up ........................41 Operation...............................42 Notes..............................42 Switching the unit on or off ......................43 Adjustments ............................. 43 Refilling ............................43 Maintenance............................44 10.1 Notes..............................44 10.2 Maintenance plan ..........................
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Page 5: Contact Addresses
+49 (0) 72 21 9711-111 Fax: +49 (0) 25 83-301-2547 Email: service@termotek.de Email: customer-service@technotrans.de Germany Germany technotrans graphics ltd. technotrans france sarl Axis One, Brunel Way ZAET “Les Haies“ Severalls Business Park Rue Albert Einstein Colchester, Essex CO4 9QX 60740 Saint-Maximin cedex... - Page 6 Contact Addresses Asia technotrans Asia-Pacific limited, Japan branch technotrans technologies pte.ltd 322 Sannomiya Venture Building 66 Kallang Pudding Road #04-03 4-1-23 Hamabe-Dori, Chuo-Ku Hor Kew Business Centre Kobe 651-0083 Singapore 329324 Phone: +81 3 5484 3180 Phone: +65 6508 6800...
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Page 7: Making Contact
Contact Addresses Making contact Please keep the following details ready (see the type plate of the 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. -
Page 8: About This Manual
About this manual About this manual Use and storage NOTE Prior to performing any work on the unit/system, read the instruction manual. The following points must be noted: • The instruction manual is an integral part of the unit/system and must be available to the operating personnel at the unit/system at all times. -
Page 9: Target Audience
About this manual Target audience When working with the unit/system, the various tasks must be assigned to specific groups of persons. Depending on the location of use, the necessary qualification of the personnel may be subject to varying statutory provisions. The operator must ensure compliance with the relevant laws. -
Page 10: Explanation Of The Various Notes
About this manual Explanation of the various notes The warning notes are preceded by signal words indicating the severity of the hazard. Compliance with the warning notes is imperative in order to avoid accidents, injuries and damage to property. Explanation of warning notices used in this manual: DANGER Short description of danger The signal word DANGER identifies an immediately threatening danger. -
Page 11: Seal Of Quality
About this manual Seal of quality The seal of quality "gdsCert" of gds GmbH (service provider for technical documentation) is a proof of quality for technical documentation. With the "gdsCert" seal of quality, the manufacturer provides proof of the high standard of the technical documentation and of the compliance with the relevant standards and guidelines. -
Page 12: Liability And Warranty
Liability and warranty Liability and warranty General information The unit/system has been manufactured in line with the state of the art as well as the recognised safety regulations and standards. Still, its use may jeopardise the health and safety of the user or third parties or cause damage to the unit/system or other property. -
Page 13: Terms Of Warranty
Liability and warranty Terms of warranty The manufacturer cannot be held liable for damage resulting from improper use, non-compliance with this manual, the employment of insufficiently qualified personnel, or unauthorised modifications. In these cases the manufacturer’s warranty is rendered void. The correct operation of the unit will be impaired if incorrect spare parts are used! The correct operation of the unit cannot be guaranteed if components are used which have not been approved. -
Page 14: Information On It Safety
SE and its subsidiaries shall not be held liable for any damage and/or loss caused by such security breaches, unauthorised access, faults, intrusion or... -
Page 15: Safety
Safety Safety General information NOTE Every person who is ordered to work on the unit/system must have read and understood these instructions and, in particular, the "Safety" chapter. If necessary, in-house instruction should be provided, taking into account the technical qualifications of the personnel concerned. The "Safety"... -
Page 16: Intended Use
Safety Intended use The unit or the system is intended solely for the application outlined in the “Description/Overview” section and only with the components supplied and approved. Using the unit for purposes other than those mentioned above is considered contrary to the intended use. The manufacturer cannot be held liable for any damage resulting from such use. - Page 17 Safety There is an increased risk of injury if the safety devices and guards are disabled. Never dismantle or disable any safety devices or guards. • Check the safety devices and guards daily for correct operation. • Report any faults and defects concerning the safety devices and guards to the customer service without delay.
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Page 18: Transport And Installation/Start-Up
Safety Transport and installation/start-up There is an increased risk of injury for persons who perform tasks for which they are neither qualified nor trained. Only persons who are familiar with the tasks, who have been informed about the associated hazards have the necessary qualifications are authorised to transport the unit. -
Page 19: Operation
Safety Operation • Operation is permissible only if all of the components are in a perfect technical state and proper operational condition and if they are used in line with the intended purpose. • Avoid any operation that compromises the safety of the unit/system. •... -
Page 20: Residual Risks
Safety Residual risks Any unavoidable, design-based residual risks (if present) are mentioned and described in this instruction manual in the corresponding sections. Use of chemicals Health hazard! The use of chemicals can present a health hazard. • When handling chemicals, always wear protective gloves, eyewear, and clothing. -
Page 21: Use Of Cleaning Agents
Safety 4.10 Use of cleaning agents No material, i.e. neither metals nor plastics, can be certified to be completely chemically resistant. Due to the large number of available additives and cleaning agents, the recipes of which are subject to change, the manufacturer cannot assume any liability for damage attributable to the influence of such substances. -
Page 22: Safety Labels
Safety 4.11 Safety labels Notes and symbols on the equipment/system, e.g. safety labels and plates, must be absolutely complied with. Do not remove them and ensure that they are fully legible. NOTE Destroyed or illegible marks/symbols must be replaced immediately. Warning –... -
Page 23: Description / Overview
Description / Overview Description / Overview General information The cooling unit is used for cooling the medium of a connected device. The temperature of the medium is maintained at a constant level between specified limits by way of the cooling process. The unit is suitable for the use of a water-glycol mixture. -
Page 24: Safety Devices
Description / Overview Safety devices • Safety devices of the refrigeration unit as per EN378, part 2 • The refrigeration circuit is secured by a high-pressure switch. The high-pressure switch is triggered, if the refrigeration circuit is overloaded and the chilling medium is thus under high pressure. The high-pressure switch is automatically reset after the triggering. -
Page 25: Foreseeable Misuse
Description / Overview ogle Foreseeable misuse The following points describe a foreseeable misuse of the unit/system: • Insufficiently trained personnel • Non-compliance with the operating data • Non-compliance with the maintenance intervals • Non-performance, incorrect performance, or incomplete performance of maintenance tasks •... -
Page 26: System Layout
System Layout System Layout Overview OUT1 OUT2 OUT3 OUT4 15591 Fig. 2: Cooling unit... - Page 27 System Layout Alarm LED Air filter Illuminated: Maximum tank fill level; Castors with brakes the functions of the unit will be Fill level indicator (tank) switched off Switch box with: Warning LED Power supply unit Illuminated: Minimum tank fill level Automatic circuit breaker Pilot LED Air-break contactor...
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Page 28: Information Concerning The Refrigerant
System Layout Information concerning the refrigerant The device contains a small quantity of a refrigerant. The refrigerants used are so-called hydrofluorocarbons (HFCs) without ozone- depleting potential (ODP = 0). It is important to comply with the following points: • Avoid damaging the pipes of the refrigeration circuit during transportation and assembly. -
Page 29: Refrigeration Unit
System Layout Refrigeration unit 6.3.1 General information If refrigeration units are used, please comply with the rules and regulations that are in force in the country where the system is set up. Information concerning the refrigerant and the filling quantities can be found in the “Technical Data”... -
Page 30: Obligation To Maintain Records
System Layout 6.3.2 Obligation to maintain records annual leak test semi-annual leak test Refrigeration hermetically sealed Refrigeration units Refrigerant unit refrigeration unit R449A as of a CO equivalent (global warming potential) of 5,0 t 10,0 t 50,0 t In accordance with the F-gases regulation (EU regulation 517/2014), the operators must maintain records about systems that are subject to statutory leak tests. -
Page 31: Transport
Transport Transport 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. WARNING Danger to persons due to heavy objects! The total weight must be taken into account for transport of the device. -
Page 32: Transport To The Installation Location
Transport Transport to the installation location WARNING Danger for persons! Increased risk of injuries through improper transport. The transport of the unit should be carried out only by suitably qualified persons who are familiar with the unit and who have been informed as to potential hazards. -
Page 33: Installation Site
Transport Installation site When selecting an installation site, observe the following instructions: • Keep the specified escape routes clear. • Ensure firm support and a horizontal position of the unit. • Comply with the data stated in the “Technical Data” section concerning the ambient temperature for operation, transport and storage when the unit is completely empty. -
Page 34: Setting Up
Setting Up Setting Up 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. WARNING Risk due to incorrect installation/start-up! There is an increased risk of injury for persons who perform tasks for which they are neither qualified nor trained. -
Page 35: Installation
Setting Up Installation WARNING Risk of injuries for persons due to heavy objects! The components mentioned above are very heavy and bulky. Always have several persons carry out the installation or dismantling or use appropriate lifting devices! NOTICE Impairment of air circulation! Impairment of air circulation leads to reduced refrigeration capacity of air-cooled versions. -
Page 36: Medium Connections
Setting Up Medium connections NOTICE Damage through dirt particles! Dirt particles in customer-provided installations (e.g. pipes, hoses, ...) may lead to malfunctions or damage to the components or unit/system. • Ensure that the customer-provided installations (e.g. pipes, hoses, ...) are free from dirt particles. - Page 37 Setting Up Cooling circuit: Connect the unit. • Medium inlet (IN, return flow) • Medium outlet (OUT, feed flow) Waste water circuit A customer-provided process water supply can be connected to the unit to dissipate the waste heat produced by the unit. Connect the unit.
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Page 38: Electrical Connection
Setting Up Electrical connection DANGER Electrical hazard! Disconnect the unit from the power supply prior to performing any work on the unit. Check whether the unit is properly disconnected from power and absolutely voltage-free. Secure it so that it cannot be reconnected. Only skilled and certified electricians are authorised to perform any work on the system. -
Page 39: Filling
Setting Up Filling WARNING Health hazard! The use of chemicals can present a health hazard. • When handling chemicals, always wear protective gloves, eyewear, and clothing. • Observe the safety data sheets. NOTICE Damage to components! Damage to the pump due to dry operation. Never start the unit when it is not, or only insufficiently, filled. - Page 40 Setting Up The unit must be filled prior to the initial start-up. NOTE • Only use the cooling medium that is specified in the “Technical data” section. • If the cooling medium level falls below the alarm limit, certain functions (e.g.
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Page 41: Final Steps After Start-Up
Setting Up Final steps after start-up 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): •... -
Page 42: Operation
Operation Operation 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. WARNING Danger to personnel! There is a risk of injury due to liquid under pressure, rotating parts, and high electrical voltage in the unit. -
Page 43: Switching The Unit On Or Off
Operation Switching the unit on or off • If the external release signal (to be provided by the customer) is interrupted, the unit will be stopped. • The device is de-energized by disconnecting the electrical connecting line. • The unit is switched on and off via a switch that is integrated in the housing. 13617 Fig. -
Page 44: Maintenance
Maintenance 10 Maintenance 10.1 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. - Page 45 Maintenance NOTICE Risk of damage to the electronic components! Take suitable measures (ESD protection measures) to prevent the electronic components from being damaged due to electrostatic discharge. Note concerning the protection of the environment The improper disposal of chemicals (e.g. additives) has a negative impact on the environment.
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Page 46: Maintenance Plan
Green: No moisture in the refrigerant. • Yellow: Moisture in the refrigerant (contact the technotrans service department). Check the refrigerant quantity with active compressor(s). • A continuous formation of bubbles can indicate a lack of refrigerant. Contact the technotrans service department. Refrigeration unit Visual inspection... - Page 47 (refrigeration circuit) local rules and regulations (e.g. F-gases regulation). specialised personnel / Contact The following types of refrigeration units must be inspected the technotrans for leaks: service department • Refrigeration units with a refrigerant filling quantity of more than five tonnes (5 t) of CO equivalent.
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Page 48: Draining Off The Medium / Refilling The Cooler With Medium
Maintenance 10.3 Draining off the medium / Refilling the cooler with medium Draining the medium: Switch the device off and disconnect the power supply cable. Keep a suitable collecting vessel ready for collecting the medium. Disconnect the connectors (feed flow, return flow). Drain the medium off via the drain hose. -
Page 49: Filter Replacement
Maintenance 10.4 Filter replacement 12845 Fig. 6: Filter (example) Filter cup Filter element Replace the filter as described below: Switch the device off and disconnect the power supply cable. If included, close the shut-off valves upstream and downstream of the filter unit. -
Page 50: Refrigeration Unit
Maintenance 10.5 Refrigeration unit 10.5.1 General information 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 hazards. -
Page 51: Refrigerant Sight Glass
Maintenance 10.5.2 Refrigerant sight glass 13374 Fig. 7: Refrigerant sight glass (example) Sight glass 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 filter drier. Symptoms of malfunctions: •... -
Page 52: Troubleshooting
Troubleshooting 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. -
Page 53: General Malfunctions
Troubleshooting WARNING Risk of injuries for persons due to heavy objects! The components mentioned above are very heavy and bulky. Always have several persons carry out the installation or dismantling or use appropriate lifting devices! Danger to personnel! There is a risk of injury due to liquid under pressure, rotating parts, and high electrical voltage in the unit. -
Page 54: Electrical Connection
Troubleshooting 11.3 Electrical connection Fault Cause Note Unit not working. No power supply. Switch the power supply system on. Check the external fuse protection. Check the supply cable for signs of damage and ensure that it is properly connected. Check the electrical circuit. Check the fuses/micro-fuses. -
Page 55: Refrigerant Sight Glass
Troubleshooting Fault Cause Note Refrigeration unit not Compressor circuit breaker has Reset circuit breaker. running or reduced tripped. refrigeration capacity. High-pressure fault. Clean the condenser (air-cooled version). Ensure that there is a sufficient amount of cooling air (air-cooled version). Air filter mat is dirty. Replace. -
Page 56: Unit-Specific
Troubleshooting 11.5 Unit-specific Fault Cause Note No or insufficient chilling The level in the medium container is Top up with medium. medium flow. too low. Check the unit for leaks. Seal the unit if necessary. Pump defective. Check and replace if necessary. Check the fuse. -
Page 57: Disconnecting The Device
Disconnecting the device 12 Disconnecting the device 12.1 Notes WARNING Risk of injuries for persons due to heavy objects! The components mentioned above are very heavy and bulky. Always have several persons carry out the installation or dismantling or use appropriate lifting devices! WARNING Danger through electric current! -
Page 58: Dismantling
Disconnecting the device 12.2 Dismantling Note concerning the protection of the environment The improper disposal of spent residual operating fluids (e.g., cleaning agents) places a burden on the environment. • Spent or residual operating fluids must not be disposed of with domestic waste. -
Page 59: Transport And Storage
Disconnecting the device 12.3 Transport and storage NOTICE Danger of frost Damage caused by freezing cooling water in the device. Completely drain the device before transportation. NOTE Transport the unit carefully and in a shock-free and vibration-free manner. Please note the following: •... -
Page 60: Recycling
Disconnecting the device 12.4 Recycling Note concerning the protection of the environment The improper disposal of reusable materials (e.g. plastics, steel and aluminium parts, electronic modules) has a negative impact on the environment. • Ensure that reusable materials are recovered for reuse. Recycling is an important contribution to the protection of the environment. -
Page 61: Technical Data And Further Information
Technical data and further information 13 Technical data and further information NOTE Information about the technical data, spare parts and conformity of the devices are prepared and provided separately. -
Page 62: Index
Index 14 Index Additional details..........61 Maintenance ..........19, 44 Maintenance schedule ........46 Maintenance, repair and overhaul ..... 19 Chemicals ............20 Making contact............. 7 Cleaning..............19 Malfunctions ..........51, 55 Conformity of the devices ........61 Manufacturer's address ........5 Contact Addresses ..........5 Medium connections .......... - Page 63 Index Type plates ............13 Target audience............9 Technical data ............61 Unit-specific ............56 Transport ..........18, 31, 59 Use and storage........... 8 Transport material..........31 Transport to the installation location....32 Warranty ............12, 13...
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