DTE CoolMaster K2 Series Operating Manual

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OPERATING MANUAL

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REVISION

CoolMaster K2 Series

Table of Contents

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Summary of Contents for DTE CoolMaster K2 Series

Page 1 OPERATING MANUAL TITLE CoolMaster K2 Series REVISION...
Page 2: Table Of Contents
OPERATING MANUAL (Translation of the original instructions) INDEX DISCLAIMER ............................................3 SAFETY INSTRUCTIONS AND WARNINGS ................................... 4 ........................................5 ORRECT APPLICATIONS ........................................ 5 NCORRECT APPLICATIONS GENERAL DESCRIPTION ......................................6 ..........................................8 DENTIFICATION TRANSPORT AND STORAGE ...................................... 9 K .................................... 9 RAINING WATER FROM ASTER N ..............................
Page 3: Disclaimer
The manufacturer reserves the right to change parts at any time to change, without prior or immediate notice to the customer. The contents of this manual may also be changed without prior warning. This is an original manual, and is valid for the machine in its standard version. For information on adjustments, maintenance and repair insofar as this guide does not provide it, please contact the technical department of your supplier.
Page 4: Safety Instructions And Warnings
WARNING! Warning of possible entrapment hazard This user’s manual was written for types similar to DTE CoolMaster K and N type machines. Therefore certain topics may not apply to your machine. For the same reason, the images may differ slightly from how your machine actually looks. The machine drawing is sent separately as an attachment with the correct dimensions and connections.
Page 5: Correct Applications
ATTENTION! In no way the machine can be stacked or overturned. This during transport and storing as well during repairs and commissioning. Even when the machine is not used it should be perpendicular at all times. ATTENTION! Not following these instruction can cause big damage to the machine. The CoolMaster K and N may only be kept inside a cool, well-ventilated, frost-free building! The CoolMaster K is only suitable for tap water of drinking quality.
Page 6: General Description
The CoolMaster is a complete plug and play water cooler with integrated water cooler tank, pump, condenser and controls. Is built for perfect cooling in closed industrial process water systems. CoolMaster sample drawing*:...
Page 7 Overview of the most common connections on the machine: NOTE! POSITION THE COVER (I) BEFORE SWITCHING ON THE MACHINE! Cooling water inlet, see P&ID Cooling water outlet, see P&ID Drainage water tank, see P&ID Filling water connection, see P&ID (not present on machines, specified as CoolMaster N) Manual filling device, see P&ID Manual filling device, see P&ID (only present on machines, specified as CoolMaster N)
Page 8: Identification
The identification plate is located on the left next to the fan. (Figure 2.1) A = Machine number/ serial number B = Machine type C = Voltage D = Maximum Current E = Number of phases F = Frequency in Hz. G = Refrigerant type H = Refrigerant mass = Maximum ambient temperature...
Page 9: Transport And Storage
These actions are general and have to been carried out, of course, if applicable for the application by qualified personal! For packaging, transport and storage, first follow the following steps; Step 1: Switch the main switch (S1) on the control panel (G) off. Step 2: Close the filling connection (D1) (not present on machines, specified as CoolMaster N) Step 3: Drain the water tank of the cooling system by opening the drainage valve.
Page 10: Commissioning
These actions are general and have to been carried out, of course, if applicable for the application by qualified personal! CAUTION! The Declaration of Incorporation of Partly Completed Machinery (if applicable) may not be put into service until a declaration of conformity to the provisions of the Machinery Directive 2006/42/EC is available for the finished machine in which it will be installed.
Page 11: Connecting Cooling Water Pipes
ATTENTION! Before making any connections to the CoolMaster, clean the external pipes. Dirt must be prevented from entering the CoolMaster. It may cause serious damage to the system and the CoolMaster. ATTENTION! The diameter of the pipes/hoses must at least match with the connections on the CoolMaster. The hoses must be reinforced with braided fibre to prevent kinking the hose.
Page 12: Connecting Drainage / Overflow Pipe (C) And (E)
CAUTION! For machines filled with a mixture of water and glycol (machines specified as CoolMaster N), the excess mix from connection (E) may not be discharged into public sewers for environmental reasons. Instead, it should be collected in suitable containers and disposed of in accordance with applicable waste management regulations.
Page 13: Water Quality
CAUTION! The CoolMaster is not suitable for use with demineralized water or water containing high levels of minerals or iron. CAUTION! The CoolMaster N is only suitable for tap water of drinking water quality mixed with the correct ratio of a suitable anti-freeze (glycol). The filling water which is used must be of good quality.
Page 14: Filling Of ( External ) Pipes And Systems Cool Masterk
Step 1: 1. All the connections must be made in accordance with §4.2. 2. Turn the air vent(s) in your system to “open”. (The venting must take place at the highest point(s) in pipe(s)) CAUTION! Do not use automatic air vents! CAUTION! Filling procedure for machines designated CoolMaster K, (see chapter §...
Page 15: Filling Of ( External ) Pipes And Systems Cool Mastern
Step 1: 1. The connections must be made in accordance with §4.2. The ball valve (BVS-1) must be kept closed, unless otherwise indicated! (See Figure 4.7) CAUTION! Filling procedure for machines designated CoolMaster N, (see chapter §4.10). Filling set for mixture of water and glycol Figure 4.7 (The fillingset is not supplied as standard) Step 2:...
Page 16 2. Install the link (BVS-5) onto the ball valve (BVS-3) (Minimum pressure 2.5 bar), (see Figure 4.11). Step 3: 1. Turn the air release valve(s) to “open”. (It is essential that the air release(s) takes place at the highest point(s) in the pipe(s)) CAUTION! Do not use automatic air release valves! 2.
Page 17 Step 4: Excess air will be released from the pipe(s) though the air release valve(s). If the water and glycol mixture spills from the air release valve(s), the external pipes/systems are filled with the water and glycol mix. 1. Turn the ball valve (BVS-3) to “closed”, (see Figure 4.15). 2.
Page 18: Filling Of The System Cool Masterk
CAUTION! To add any chemicals or other substances, please consult the supplier. Fill the CoolMaster with water (fill automatically or manually): 1. Auto fill (D1) (a power supply is required; a minimum filling pressure of 2.5 bar is required), (see Figure 4.19). 2.
Page 19: Filling Of The System Cool Mastern
CAUTION! To add any chemicals or other substances, please consult the supplier. CAUTION! To prevent the heat exchange and/or other parts from freezing, the mixing ratio of the water and glycol mix must be checked weekly by taking a sample from the tank.
Page 20: Eaerating
CAUTION! DO NOT START THE WATER PUMP BEFORE IT IS FILLED WITH LIQUID AND DEAERATED! This machine is fitted with a bypass and will therefore the water pump automatically be deaerated. Step 1: To ensure the whole system is vented, make sure the removable cap (I) of the machine is on it and tank cap is turned off.
Page 21: Setting Thermostat ( If Applicable )
CAUTION! COVER(I) MUST BE PLACED, BEFORE STARTING UP THE MACHINE! CAUTION! It is important that the values in the P&ID are adhered to, otherwise damage to the compressor may occur! When temperatures set incorrectly the guarantee claim may expire! CAUTION! This machine is equipped with a bypass, which is erected between water supply and water return pipe inside the CoolMaster.
Page 22: Commissioning After Long Standstill
CAUTION! The Declaration of Incorporation of Partly Completed Machinery (if applicable) may not be put into service until a declaration of conformity to the provisions of the Machinery Directive 2006/42/EC is available for the finished machine in which it will be installed. CAUTION! Machinery specified as CoolMaster K and N, first follow the steps from chapters §4.1 till 4.12.
Page 23: Alarm Signals (If Applicable)
Fault → Possible cause → Check and solution 1. HP Alarm 1.1. High pressure in the system 1.1. Check the condenser for dirt and and clean with compressed air if necessary 1.2. Installation Removable cover 1.2. Contact your supplier 2. Level Alarm 2.1.
Page 24: Fault Analysis
Have all checks and repairs performed by a certified technician! Fault → Possible cause → Check and solution 1. Unit does not start 1.1. Faulty wiring 1.1. Check wiring and connections 1.2. Components down to earth 1.2. Check and replace 1.3.
Page 25: Maintenance And Cleaning
Authority (competent bodies, policy, regulation etc.) Conditions of parts (exposure and/or corrosion) Results of previous inspections DTE recommends a minimum inspection interval as given in chapter (§7.1 If a problem and/or advise is needed from our technical staff, please always mention: Serial number...
Page 26: Minimum Inspection - Interval Scheme
All inspections should be performed by an authorized technician! CAUTION! BEFORE OPENING THE MACHINE, ALWAYS ENSURE POWER SUPPLY IS COMPLETELY DISCONNECTED! Inspection interval Every Every Inspection points Weekly monthly 6 months 12 months Mechanical Visual check on damage outside of the unit Visual check fans motor(s) and fan blade(s) on damage and prevalence Visual (and auditive) check on defects...
Page 27 The maintenance and leak-tightness checks should be carried out, according to the local legislation. For the Dutch guidelines, the maintenance and leak-tightness checks should be carried out according to the table below. Only certified companies employing qualified technicians are allowed to carry out refrigeration work or inspections of refrigeration installations.
Page 28: Cleaning Of The Machine
CAUTION! ONLY APPLIES TO THE EXTERIOR CASING! Step 1: Before cleaning the machine, make sure you completely disconnect the power supply. Step 2: To clean the machine use a soft brush, with lukewarm water with a non-aggressive cleaner. Step 3: Then rub the machine dry with a soft, dry cloth. Unless explicitly stated otherwise the machine must not be cleaned with a high-pressure cleaner and/or other powerful water jets! Step 4: For additional cleaning instructions, see appendix §9.2 Water Treatment.
Page 29: Removal
The CoolMaster consists primarily of stainless steel, copper, brass and aluminium. The CoolMaster is also compressed with a refrigerant which is specified in the “P&ID” and the relevant safety data sheet. Removal of the CoolMaster must be carried out in accordance with local or national legislation. Contact your government for instructions.
Page 31: Connection Diagram Filling The System
Figure 9.1...
Page 32: Water Treatment
INTRODUCTION Semi-closed and closed cooling systems are used in many processes. An efficient and effective cooling system is needed for a process to function without problems. Generally such cooling systems contain between 0.5 and 5.0 m³ water, which is normally topped up with tap water. The tap water available is often, technically speaking, of poor quality: •...
Page 33 Specific water treatment should be used if one or more values cannot be maintained or achieved. Water treatment products can be used for a wide variety of applications in this case. DTE has a water treatment in the form of PollutionMaster. This product can optionally be supplied. If the temperature of the water exceeds approx.
Page 34: Guideline For Water Quality In Dte Installations
Water quality for use in all DTE installations is prescribed in this general guideline. Water quality used in DTE installations should meet this standard at all times. Standard values for water quality: Acidity: PH 7 < PH 9,5 Chloride: < 50mg / L Conductivity: 150 µS <...
Page 35: Manual For Locked Water Pump After A Long Period Of Stand Still
DISCONNECTED! DTE uses reputable components in its products, whereby DTE will reduce the risk of faults in its machines. This also applies to the water pumps. These pumps are made with a stainless steel fan, a high quality pump house and a “Mechanical seal”...
Page 36 Checking the direction of rotation - For the Grundfos CM pump: The description below applies to three-phase motors only. The motor fan cover has an installation indicator, (see Figure 9.4). Based on the motor cooling air, it indicates the direction of rotation of the motor.
Page 37: User Manual Thermostat ( If Applicable )
‘’Err’’ Memory reading error ‘’Erp’’ - Probe error, not viewed in display ‘’Eri’’ Internal parameter error. In this case, enter the above DTE-configuration ‘’ALH’’ - High temperature alarm ‘’ALL’’ - Low temperature alarm (temperature is 5 degrees lower then ‘’SET”) ‘’ALE’’...
Page 38: Instructions Of Partly Completed Machinery ( If Applicable )
CAUTION! ONLY APPLICABLE TO THE OUTSIDE OF THE CASING! CAUTION! When there is an Partly Completed Machinery, the machine must be equipped with an external thermal protection and main switch with the correct range to ensure safety! CAUTION! The Declaration of Incorporation of Partly Completed Machinery may not be put into service until a declaration of conformity to the provisions of the Machinery Directive 2006/42/EC is available for the finished machine in which it will be installed.
Page 39: Eu-Declaration Of Conformity
EU declaration: Manufacturer: D.T.E. B.V. Address: Westerbroekstraat 18 7011 EX GAANDEREN / HOLLAND Hereby certifies that: The CoolMaster meets the requirements of the Machinery Directive (Directive 2006/42/EC, as amended), and the national legislation implementing this Directive; Meets the provisions of the following other EU directives. 2014/35/EU Low Voltage Directive 2014/30/EU EMC directive 2014/68/EU Pressure Equipment Directive (PED)
Page 40 UKCA declaration: Manufacturer: D.T.E. B.V. Address: Westerbroekstraat 18 7011 EX GAANDEREN / HOLLAND Hereby certifies that: The CoolMaster meets the requirements of the Machinery Directive (Directive Supply of Machinery (Safety) Regulations 2008, as amended), and the national legislation implementing this Directive; Meets the provisions of the following other UKCA directives: Electrical Equipment (Safety) Regulations 2016 Electromagnetic Compatibility Regulations 2016...
Page 41: Guarantee
One or more components in this CoolMaster are sealed. Breaking these seals or adjusting components which are not sealed, may void your guarantee. Always contact your supplier. When claiming one or more components under the guarantee, these components must be returned to the supplier uncleaned and in their original state. Otherwise, the guarantee conditions on this machine apply as described in the general conditions of delivery and payment.
Page 43: Technical Information
➢ ➢ ➢ ➢ & & ➢ ➢ ➢ ➢ ➢ ➢ ➢ ➢ ➢ ➢ ➢ ➢ *Technical information is sent as an attachment to the technical operating instructions!