Hydac RFCS Series Installation And Maintenance Manual
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Hydac RFCS Series Installation And Maintenance Manual

Hydac RFCS Series Installation And Maintenance Manual

Stand allone chiller
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Stand allone chiller

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Summary of Contents for Hydac RFCS Series

  • Page 1 Installation and maintenance manual Stand allone chiller...
  • Page 2 IW = non-ferrous metal parts, in contact with water DI = free from non-ferrous metal, in contact with water C = chemical media Other information (optional, for example UL) H.I.B Hydac International Page 2 of 36 Version: G/DV Date: 11.01.2023...
  • Page 3 No part of this Installation and maintenance manual may be reproduced or duplicated in any form (printing, photocopying or any other process) without the permission in writing from the manufacturer. H.I.B Hydac International Page 3 of 36 Version: G/DV Date: 11.01.2023...

  • Page 4: Table Of Contents

    Description of operation of compressor-cooled (RFCS) ........17 6.2.1 Function diagram compressor-cooled system (RFCS): ........18 Description of operation of water-cooled systems (FWKS) ......18 6.3.1 Functional diagram of water-cooled system (FWKS): ........18 H.I.B Hydac International Page 4 of 36 Version: G/DV Date: 11.01.2023...
  • Page 5 Scrapping ......................35 18.3 Refrigerant (optional) ..................35 18.4 Coolant ......................35 18.5 External water (optional) ................... 35 19.0 Operating faults and causes of faults............... 35 20.0 Annex ........................... 36 H.I.B Hydac International Page 5 of 36 Version: G/DV Date: 11.01.2023...
  • Page 6 Flow chart ......................36 20.5 Wiring diagramm ....................36 20.6 Special functions (optional) ................36 20.7 Test report ......................36 20.8 Declaration of Incorporation / CE Declaration of Conformity ......36 H.I.B Hydac International Page 6 of 36 Version: G/DV Date: 11.01.2023...

  • Page 7: Foreword

    Please check the type of manual (see Annex, Type List) against the label on you NOTE device. This installation and maintenance manual is only valid for the device mentioned in annex. H.I.B Hydac International Page 7 of 36 Version: G/DV Date: 11.01.2023...

  • Page 8: Machinery Directive 2006/42/Ec

    This heading is used when an exceptional feature should be taken notice of. MANDATORY: This heading is used when technical rules or regulations require that a course of action be observed. MANDATORY H.I.B Hydac International Page 8 of 36 Version: G/DV Date: 11.01.2023...

  • Page 9: Warning Notices And Symbols Used

    Danger of freezing WARNING INFORMATION Warning against cuts Position of the centre of gravity MANDATORY MANDATORY MANDATORY MANDATORY Wear eye protection Wear foot protection Wear protective clothing Wear protective gloves H.I.B Hydac International Page 9 of 36 Version: G/DV Date: 11.01.2023...

  • Page 10: Personal Protective Equipment (Ppe)

    Observe regulatory information Observe the following regulatory information and directives:  Legal and local regulations for accident prevention  Legal and local regulations for environmental protection  Country-specific regulations, organisation-specific regulations H.I.B Hydac International Page 10 of 36 Version: G/DV Date: 11.01.2023...

  • Page 11: Qualification And Training Of Personnel

    Any guard preventing accidental contact of moving parts must not be removed when the system / unit is running. Take appropriate steps to preclude any hazard by electric power. (For relevant details see the rules of the VDE and the local energy supply companies). H.I.B Hydac International Page 11 of 36 Version: G/DV...

  • Page 12: Notes On Safety For Maintenance, Inspection And Assembly Work

    Modification of or changes to the chiller / unit are only permitted after previous consultation of the manufacturer. Original spare parts and accessories authorised by the manufacturer serve for ensuring safety. The use of other parts will void the liability for the resulting consequences. H.I.B Hydac International Page 12 of 36 Version: G/DV...

  • Page 13: Reference

    Transport damage, on basis of suitability and specification installation error Contact with coolant Organisational, maintenance Hoses hard to reach schedule of the hoses, safe access for filling and draining H.I.B Hydac International Page 13 of 36 Version: G/DV Date: 11.01.2023...

  • Page 14: Residual Risks Of Electric System/Electronics

    Any guard preventing accidental contact of moving parts must not be removed when the chiller / unit is running. Take appropriate steps to preclude any hazard by electric power. Affixed on the packaging instructions for transport and storage must be observed! WARNING H.I.B Hydac International Page 14 of 36 Version: G/DV Date: 11.01.2023...

  • Page 15: Improper Operatinig Modes

    Work on the system may only be carried out by trained specialists in the fields of electrical, mechanical or refrigeration engineering. The area of responsibility, competence and supervision of the personnel must be precisely regulated by the operator. H.I.B Hydac International Page 15 of 36 Version: G/DV...

  • Page 16: Plant Log (Compressor-Cooled System)

    The manual must be updated by specialist personnel whenever the coolant circuit is broken into and whenever repair, maintenance, leak detection and leakage tests are performed. Such work must always be performed in compliance with state-of-the-art technical standards. H.I.B Hydac International Page 16 of 36 Version: G/DV...

  • Page 17: The Device's Emission Of Airborne Noise (See Technical Data Sheet)

    A motorized control valve mounted in the cooling circuit controls the required cooling capacity as a function of the measured coolant temperature via the temperature sensor and the temperature controller. H.I.B Hydac International Page 17 of 36 Version: G/DV Date: 11.01.2023...

  • Page 18: Function Diagram Compressor-Cooled System (Rfcs)

    SI- Index 7 to 9 Saturation index (SI) (Delta pH-value) -0,2<0<+0,2 Total hardness °dH <6 Conductivity µS/cm >200 filterable material mg/l mg/l <30 Chloride mg/l <100 Free chlorine mg/l <0,5 H.I.B Hydac International Page 18 of 36 Version: G/DV Date: 11.01.2023...

  • Page 19: Heating Operation (Optional)

    The chiller / unit has a weight of (see appendix, Technical Data). WARNING All existing eyebolts must be equally loaded! Use only a portion of the existing lifting lugs are not allowed WARNING H.I.B Hydac International Page 19 of 36 Version: G/DV Date: 11.01.2023...
  • Page 20 For transport, observe the location of the centre of gravity Wear safety boots during transport. Transport of S7 with steel tube (diameter 40 – 50mm) and with transport belts Transport of G7/G8 with traverse or forklift! schematic diagrams H.I.B Hydac International Page 20 of 36 Version: G/DV Date: 11.01.2023...

  • Page 21: Transport Monitoring

    The chiller has been checked at the factory as regards its seals. It is certified that the chiller has been subjected to an electrical safety test in the factory before being dispatched. (See test report) H.I.B Hydac International Page 21 of 36 Version: G/DV Date: 11.01.2023...

  • Page 22: Technical Data And Type Plate

    Place the unit only on level foundations of good bearing capacity. Align the unit horizontally and vertically to start-up. WARNING Before you install the unit outdoors or in areas where there is danger of frost, contact the Manufacturer WARNING H.I.B Hydac International Page 22 of 36 Version: G/DV Date: 11.01.2023...

  • Page 23: Hydraulic Connection

    If parts of the cable or other connected elements are higher than the intended level of liquid placed as the return flow of the coolant at a stationary plant is to be prevented with proper facilities. ATTENTION H.I.B Hydac International Page 23 of 36 Version: G/DV Date: 11.01.2023...

  • Page 24: Electrical Connection

    As a rule, work on the electrical system must be carried out by expert personnel; the valid wiring diagram and the VDE guidelines must be observed. Compare the mains voltage at side with the nameplate of the unit. WARNING H.I.B Hydac International Page 24 of 36 Version: G/DV Date: 11.01.2023...

  • Page 25: Commissioning

    Re-attach the maintenance flap (optional) 6. Check: Leaktightness of the supply lines ATTENTION The chiller may only be operated with closed housing. Otherwise it can cause failure of the device. ATTENTION H.I.B Hydac International Page 25 of 36 Version: G/DV Date: 11.01.2023...
  • Page 26 D2 / D3 / D4 G4 / G5 / G6 / G7 / G8 G2 / G3 G0 / 10HE schematic diagrams Pos. description filling min./max. level Draining / ball valve H.I.B Hydac International Page 26 of 36 Version: G/DV Date: 11.01.2023...

  • Page 27: Empty The Tank (Optional)

    (every three months recommended) Customer-specific Dirt trap for See 13.5 Dirt trap cleaning / external water (every three months and after replacing of the metal sleeve (optional) commissioning recommended) H.I.B Hydac International Page 27 of 36 Version: G/DV Date: 11.01.2023...

  • Page 28: Maintenance Generally

    A soiled filter mat will cause the refrigerating capacity of the unit to NOTE decrease. As a result of the additionally increasing power consumption of the compressor, the efficiency of the plant / chiller will drop considerably. H.I.B Hydac International Page 29 of 36 Version: G/DV Date: 11.01.2023...
  • Page 29 Pull filter away from the cooler G4,G5,G6,G7,G8,D3,D4 Schematic diagrams Description Pos. Slide the filter upwards G0, D2, D5 Schematic diagrams Pos. Description Remove the screws (2x) Remove cover and remove filter mat H.I.B Hydac International Page 30 of 36 Version: G/DV Date: 11.01.2023...

  • Page 30: Cleaning The Dirt Trap - External Water (Optional)

    13.5 Cleaning the dirt trap - external water (optional) description Pos. Turn the chiller off and secure it against inadvertent Make sure the water supply is blocked. Screw out, clean and reinsert the strainer H.I.B Hydac International Page 31 of 36 Version: G/DV Date: 11.01.2023...

  • Page 31: Replacing The Particle Filter (Optional)

    14.0 Guarantee terms and conditions For the warranty provided by us, please refer to the General Conditions of Sale and Delivery of HYDAC Cooling GmbH. You will find these under www.hydac.com / AGB (General terms and conditions). Damage and functional faults caused by incorrect handling or failure to observe the operating instructions do not full within the terms of the guarantee.

  • Page 32: Shutdown Of The Unit

    VDE guidelines must be observed. Compare the mains voltage at site with the nameplate of the unit. WARNING After two short-circuit shutdowns, the power, motor and main switch (if present) must be revised or replaced. WARNING H.I.B Hydac International Page 34 of 36 Version: G/DV Date: 11.01.2023...

  • Page 33: For Waste And Recycling

    18.5 External water (optional) The external water system must be completely emptied by to avoid frost damage. WARNING 19.0 Operating faults and causes of faults See controller manual. H.I.B Hydac International Page 35 of 36 Version: G/DV Date: 11.01.2023...

  • Page 34: Annex

    20.2 Spare parts list 20.3 Dimension sheet 20.4 Flow chart 20.5 Wiring diagramm 20.6 Special functions (optional) 20.7 Test report 20.8 Declaration of Incorporation / CE Declaration of Conformity H.I.B Hydac International Page 36 of 36 Version: G/DV Date: 11.01.2023...
  • Page 35 USER MANUAL Temperature Controller Display HIB123 Part-No.: 3756766 Document Version: I...
  • Page 36 User Manual | Temperature Controller Display HIB123 Part-No.: 3756766 Doc.-Version: I 1. GENERAL NOTES a) Control Elements The display is operated by pressing keys. Key 1  Increase a value  Navigation Key 2 DOWN  Decrease a value  Navigation Key 3 ...
  • Page 37 User Manual | Temperature Controller Display HIB123 Part-No.: 3756766 Doc.-Version: I b) Display Elements A seven-segment indicator with three digits shows parameters and actual values. If the value can’t be displayed due to the limited number of digits, the display shows . Five vertically arranged LEDs indicate which measurement refers to the display value.
  • Page 38 User Manual | Temperature Controller Display HIB123 Part-No.: 3756766 Doc.-Version: I 2. BASIC FUNCTIONS Once the chiller is powered on, the display initializes and returns to home screen. a) Home Screen If the chiller is in standby mode, the display shows „OFF“. If the chiller is turned on, the display shows the actual temperature.
  • Page 39 User Manual | Temperature Controller Display HIB123 Part-No.: 3756766 Doc.-Version: I b) Error messages in home screen Error messages (warnings & alarms) are automatically displayed in the home screen whenever an error is pending. At the same time, the red status LED will flash (for a warning) or light up continuously (for an alarm).
  • Page 40 User Manual | Temperature Controller Display HIB123 Part-No.: 3756766 Doc.-Version: I d) Parameter group USR (Parameterlist) Parameter group USR: parameter list for customers Not all parameters in the USR group are listed. The parameter selection is dependent on the target system and the current control mode.
  • Page 41 User Manual | Temperature Controller Display HIB123 Part-No.: 3756766 Doc.-Version: I KK 3 | nominal value, flow temperature Adjustable: For fixed-value closed-loop control Display only: for closed-loop control with ambient temperature reference  depends on chiller Notice: corresponds to the value when the SET button is pressed in the home screen (for measured value LED °C3) KK 3 | Set point offset to ambient temperature ...
  • Page 42 User Manual | Temperature Controller Display HIB123 Part-No.: 3756766 Doc.-Version: I e) Parameter group OPH (Operating hours) The parameter group OPH shows the operating hours of each component (actuators). Example: 0_H = 1 0_L = 85  Operating time of the compressor is 1085 hours (1 * 1000 + 85). Parameter Component / Actuator Multiplication factor...
  • Page 43 User Manual | Temperature Controller Display HIB123 Part-No.: 3756766 Doc.-Version: I 3. ERROR CODES Once an error (warning or alarm) is present, the error code is displayed automatically. The following tables give you a complete overview over all error messages. Please note that not all error codes are displayed because the technical requirements therefore are maybe missing.
  • Page 44 User Manual | Temperature Controller Display HIB123 Part-No.: 3756766 Doc.-Version: I Warnings Code Short description Causes & Actions refill the coolant up to the MAX-mark (tank)  Low tank level causes: leakage, evaporation, defective level switch clean or change air filter ...
  • Page 45 User Manual | Temperature Controller Display HIB123 Part-No.: 3756766 Doc.-Version: I Alarms Code Short description Causes & Actions check coolant circuit  Flow rate too low causes: defective pump/valves/hoses, defective flow sensor, soiled filter (if present) open switch cabinet and reset motor circuit breaker ...

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