Bruker AXS Typ BR 058-31 Technical document

Mounting and
Operating Manual
for
Water Chiller
Typ BR 058-31
ERL 3000 TA
Deckblatt BR 058-31 e.doc/Ausgabe 27-2010

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Table of Contents
Notice 3
1 User Information 4
2 List of Danger Notices 5
2.1 Material-related dangers 6
2.2 Process-related dangers and process documentation 6
2.3 Analysis of process dangers 7
3 Designated/Intended usage 8
4 Unpacking and handling 8
5 Transport 9
6 Storage 9
7 Assembly and Installation 10
7.1 Hydraulic connection 10
7.2 Electrical connection 10
7.3 Setting up 10
7.4 General Information 11
8 Application, Function and Description 12
8.1 Description - refrigeration unit 13
8.2 Safety facilities 14
8.3 Monitoring facilities 14-15
9 Putting into operation and operating 15
9.1 Safety checks before putting into operation 15
9.2 Safety checks during operation 15
9.3 Training and performance 16
9.4 Accident analyses 16
9.5 Management of changes in personnel 16
9.6 Preparation for putting into operation 16
9.7 Switching on when putting into operation 16
10 Maintenance 17
10.1 Maintenance for the operator 17
10.2 Notes on the replacement of components 18
11 Warranty provisions 18
12 Taking out of operation 18
13 Breakdown: What is to be done if ...? 19
14 Information about Spare Parts 19
15 Details about Disposal and Recycling 19
16 Rules for the Owner/Operator 19
16.1 Rules referring to the refrigeration unit 19
16.2 Planning for emergencies and assignment 20
16.3 Operational regulations and safety practices 20
Appendices

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Notice
This document is included in the technical documentation of the companies Lahntechnik
GmbH / Duotemp Kältetechnik GmbH. All rights pertaining to this documentation, especially
the right to reproduction and distribution as well as the translation thereof lies in the hands
of the companies Lahntechnik / Duotemp Kältetechnik GmbH GmbH, even in cases of
copyright registrations.
No part of this documentation may be reproduced or reprinted, duplicated or distributed
under usage of electronic systems in whatever form without previous written consent from
the companies Lahntechnik GmbH / Duotemp Kältetechnik GmbH.
Errors and technical modifications reserved.
Lahntechnik GmbH / Duotemp Kältetechnik GmbH is not liable in any way whatsoever for
mistakes or possible mistakes in this documentation. Liability for direct and indirect
damage, the results thereof being related with the delivery or non-making use of this
documentation is excluded insofar as the law permits.

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1 User Information
The contents of these operating instructions are targeted on a number of groups of persons.
At least the relevant chapters are to be read and understood for the particular group of
persons.
Safety Instructions
Safety instructions indicated in the Operating Instructions
documentation are to be strictly adhered to at all times.
Safety instructions are labelled with a danger symbol:
The construction, layout and development of this refrigeration unit are
based on and according to the following national and international
regulations:
EC Machinery Directive 2006/42/EC
EC Low Voltage Directive 2006/95/EC
EC-EMC-Directive 2004/108/EC
EC Pressure Equipement Directive RL/97/23 EC
EN 378:2008 T1/T2/T3/T4 Refrigerating Systems and Heat Pumps
EN 60529 Degrees of Protection provided by Enclosures
EN ISO 12100-1, -2 Safety of Machinery
EN ISO 13857
EN 60204-1 Safety of Machinery - Electrical Equipment of Machines
EN 61000-6-2 Electromagnetic Compatibility (EMC)- Generic Standards – “Emission“
EN 61000-6-2 Electromagnetic Compatibility (EMC)- Generic Standards – “Immunity”
BGR 500 Accident Prevention Regulation Refrigerating Systems and Heat Pumps

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2 List of Danger Notices
The following list is not guaranteed to be fully complete. It is only an indication of the collectively
most important dangers.
Place Symbol Description How can I avoid the danger?
Elektric
Danger through electric current
As with all electrical work, there is the
danger of electric shocks, short-
circuits etc.
⇐All maintenance work, especially electrical
work, may only be carried out by suitably
trained and qualified persons
⇐Isolate the refrigeration aggregate from the
mains supply before staring maintenance work
⇐The main switch is to be fitted with a suitable
padlock
Cooling tank, cooling
system with pump,
refrigeration unit with
cooling medium
piping
Danger through burns
e.g. during maintenance, cleaning or
fault corrections
⇐Wait till parts cool down to under 40°C
⇐Use protective gloves:
Complete aggregate Danger of tripping-over through
cables and leads ⇐Lay-out all conduit so that no-one can trip-over
it and/or thereby damage it or themselves
Complete aggregate Danger through materials and
other substances (or the other
components thereof)
⇐All information about dangers has to be made
easily accessible to the operators and made
available nearby
⇐Only suitable trained personnel
Complete aggregate Danger through internal/external
contact with vapors and liquids
⇐Observance of the danger datasheets
⇐Customer-sided filling of cooling medium is to
be documented
Complete aggregate Danger through suspended loads
⇐Do not stand under suspended loads
⇐Make us of suitable and certified lifting
machinery (total weight- see technical data
page Fehler! Textmarke nicht definiert.
⇐Always wear safety shoes:

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2.1 Material-related dangers
Cooling agent and cooling oil
Physical data, heat resistance, chemical resistance, reactivity data, as well as chronic and acute
toxicity data are documented in safety datasheets of the manufacturer. Customers are hereby
recommended to acquire these documents.
The customer´s-own cooling medium should be documented on the side of the customer.
Corrosion tendencies on plant components: generally there is no danger of corrosion.
The tank for the cooling systems and pumps, as well as the housing components are generally
manufactured in stainless steel (CrNi-St). Therefore it cannot be ruled out that certain cooling
agents can cause corrosion over the years and thereby the possibility for leakages, especially
when the concentrations are not adhered to.
All information about dangers should be handed out and/or at least made easily available to those
persons who are either involved in the system, or the potential dangers thereby through the
individual materials.
2.2 Process-related dangers and process documentation
The pipework & instrument flowchart is presented in the operating instructions.
The cooling agent circuit is enclosed in a closed system. A systematic cooling agent leakage is not
possible.
The refrigeration unit is constructed so that it protects itself from straying above the designated
max. value and below the min. value, via
- a high-pressure cut-out
- a low-pressure cut-out
- a circuit-breaker (motor safety switch) and fuses
- a fluid level indicator
If the high-pressure cut-out fails, then the circuit will burst at its weakest point. As the cooling circuit
is enclosed in a housing, in the case of a burst, plant and persons in the surrounding area are
sufficiently protected. Cooling agent and cooling oil will however leak out In this case the safety
datasheets for the corresponding medium are to be consulted. And in addition, the deployment
regulations are to be adhered to.
If the low-pressure cut-out fails, there is a possibility of the customer-sided cooling medium
freezing. Generally the plate heat exchanger bursts internally. There is a possibility of cooling
agent and cooling oil penetrating into the customer-side cooling medium, i.e. customer-sided
medium gets into the cooling agent circuit. In this case the safety datasheets for the
corresponding medium are to be consulted. Also consult the chapter “Analysis of process
dangers“. The unit will most likely suffer the fate of a write-off.
In some models, instead of the plate heat exchanger there is a specially coiled heat transfer pipe
deployed as evaporator, which is submersed in the tank. In this case the danger of freezing is
eliminated. The need for a low-pressure cut-out is likewise relinquished.
If the fluid level indicator fails,then the customer-sided cooling medium in the tank can sink so low
that the pump(s) run dry. This can lead to overheating and the pumps catch fire.

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If the fluid tank is overfilled with customer-sided cooling medium, then this overflows. The tank
volume capacity is given in the operating instructions.
As protection against a customer-sided closed slide valve, the units have a continuous bypass,
between forward & return flows that insures that the pumps never work against a closed slide
valve. In some applications, a pressure-controlled bypass is installed, depending on customer
requirements. This only opens above a preset pressure and ensures that the system is never
exposed to to a pressure higher than that preset.
If the refrigeration system is lockable, then the circuit which is lockable is secured with an
additional high pressure switch. This means that cooling agent can never be locked in a non-
secured sub-circuit.
Technical standards are mentioned in the operating instructions.
Technical and safety-related data are listed in the operating instructions.
Electrical data for mains connection is likewise to be found in the operating instructions.
Technical classification, as well as electrical circuit diagrams are similarly to be found in the
operating instructions.
Before leaving the factory, the unit is tested thoroughly for safety, performance and function.
2.3 Analysis of process dangers
Special attention here at operational location: a series of analyses in connection with the listed
material-related and process-related dangers is to be recommended.
Special attention here at operational location: regular analysis in relation to potential for fire &
explosion danegrs, as well as aggressive media in the air and cooling medium is recommended,
e.g. via local gases or fluids, especially the danger of fire through the presence of oil mist in and
around the aggregate.
Special attention here in connection with the user on-site, a follow-up analysis in relation to the
listed material-related and process-related dangers is recommendable, e.g. max. pump pressure
(pump performance characteristics are to be found in the operating manual) in relation to the
permitted pressures of the customer-side plant components, etc.
It is recommended to carry out the analysis every 5 years.
It is recommended to deploy employees from different disciplines for the analysis.

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3. Designated/Intended Usage
This cooling medium device serves the cooling and transporting of cooling medium.
In certain cases heating has been installed. This is for heating the medium.
All inappropriate uses (normally foreseeable misuse), with incorrect cooling media is not
permitted and can:
¾lead to life-endangering inuries to persons
¾lead to damage to the equipment
¾lead to unforeseeable further dangers
4. Unpacking and Handling
Before and during unpacking of the equipment, a visual check must be made to detect any
possible damage that occurred in transit.
Please be on the look-out for loose parts, dents, scratches, etc.
Any possible damage is to be reported immediately to the carrier (Note the 'Provisions for
Cases of Damage'). Otherwise the 'General Terms and Conditions for Supplies and
Services' of ZVEI (Zentralverband der Elektrotechnischen Industrie, (Central Association of
the Electrical Engineering Industry) Frankfurt/M.) in the latest version apply.
Before the packaging material is disposed of, it must be checked to see whether there are
any loose functional parts in it.
For the processing of claims under the warranty, we would ask for the exact details of the
defect (possibly a photo) as well as for the indication of the type designation and the serial
number of the equipment.
In order to protect the equipment from damage, it may only be transported and stored in the
position in which it is used. Non-observance will result in the loss of warranty.

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5 Transport
Place Symbol Description How can I avoid the danger?
Complete aggregate Danger through suspended loads
⇐Do not stand under suspended loads
⇐Make us of suitable and certified lifting
machinery (total weight- see technical data
page Fehler! Textmarke nicht definiert.
⇐Always wear safety shoes:
- Take heed of the dimensions and weight in the corresponding datasheets
- Transport only with pallete bogey, fork-lift truck or lifting crane
- Transport the aggregate without water and standing
- all cran hooks if available must be evenly loadable
The use of less than the existing crane hooks are not allowed.
-
6. Storage
-Storage conditions for the product
The device is to be stored dry, free of dust and frost-free.

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7. Assembly and Installation
-Stipulations for mounting/anchouring
-Installation plan for application of the medium, cooling agent and electrics (flowchart,
dimensioned drawing, electric plan)
-Mounting & assembly conditions
-Permitted environment (temperature, humidity, vibration, electromagnetic radiation,
impacts, ...)
-Emission descriptions(e.g. vibration, noise, radiation, ...)
7.1 Hydraulic connection
Connections and the laying of piping for liquids are to be carried out by skilled and qualified
persons observing the technical rules. Facilities for bleeding the external medium circuit are
to be fitted.
7.2 Electrical connection
Electrics for cooling device according to current diagramme (see appendix).
Rotational direction is to be checked at the pump (cable connection), at the ventilator
(optical), at the compressor (loud noise). In case of the wrong rotational direction check if it
is only one component in the wrong direction, or all components. If it is only one
component, then a phase has to be changed for the component (exchange L1 and L2). If
all components are in the wrong direction then a phase has to be exchanged at the main
connection for all components involved (exchange L1 and L2).
Provide for protection by fuse(s) in accordance with the equipment’s power consumption
(see technical data on the rating plate).
ATTENTION: The mains voltage and the mains frequency
must match the rated values shown on the equipment's rating
plate.
Work on electrical systems may only be carried out by skilled
and specialised personnel. The relevant local safety
regulations are to be observed.
7.3 Setting up
Set up the cooling equipment at its intended place in such a way that the connection ends
are readily accessible.
The equipment must be set up so that it is absolutely horizontal and stable.
Setting up sheet- see Appendix.
Indoor-Setting up
The cooling aggregate is to be erected in a frost-free room on a flat, level floor with
sufficient load-carrying capacity.
Outdoor-Setting up
Installation of the unit outside requires various options: Winter pressure control,
compressor crankcase heating.
Outside mounting location must be protected by a roof with appropriate
distance to the chiller (min. 1m above fan).
Outside mounting without protection is not permitted.

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A foundation-based anchorage as well as cross-ply or vibrations damper are not
neccessary.
Cooling aggregate and consumer are generally to be based at the same level.
For other mounting positions- contact the manufacturer.
For fault-free operation of the equipment, as well as the providing corresponding free space
around for maintenance work, the minimum distances recommended are to be adhered to.
In the case of units fitted with rollers, then these rollers are to be secured in position to
protect them from rolling out of position. Many units are actually fitted with 2 rollers with
interlocks to stop them from moving once in position. Press the brake lever downwards to
lock in position.
7.4 General Information
For transportation, we recommend that the equipment’s liquid tank be emptied. For
handling please always keep the equipment in the operating position.
Work on the equipment may only be carried out by trained and qualified persons. The
appropriate safety and environmental protection regulations are to be observed. See
declaration of conformity and/or chapter 1.
The equipment was checked in the works to ensure its tightness.
It has been certified that the item of equipment was subjected to an electrical safety check
in the works before being dispatched. Hence, according to BGV A3, this relieves the
owner/operator of the obligation to carry out a check or to have a check carried out on the
electrical system of the equipment to ensure that it is in the proper working state before
the equipment is put into operation for the first time.
Operating the unit with water temperature below <12°C requires
antifreeze in adequate dosage to avoid damage caused by freezing
up, preferably Antifrogen N.
Please note that though the insert limit extends downwards the
refrigerating capacity changes considerably. Moreover the pump
capacity has to be checked. Please consult an expert before
reorganizing!

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8. Application, Function and Description
8.1 Description- refrigeration unit
Refrigeration of the user cooling medium generally takes place in an insulated open vessel
via plate heat exchanger or a special heat transfer pipe as evaporator. The heat taken up in
the cooling agent evaporator is released from the air-cooled condenser into the
surroundings or depending on model, into a local water supply über via water heat-
exchanger. Alternatively, the refrigeration unit can also be built as thru-flow cooler without
tank and pump or as a closed system or as immersion cooler.
Regulation of the medium temperature takes place via electronic temperaturre regulator or
through a customer-sided software program.
Through the installation of a time relay, there is a standstill time of 4 minutes when the
refrigeration unit is switched on(to protect the compressor from “chopping”). The
refrigeration unit does no cooling during this time! There is a possibility of a malfunction
message in this time!
Function and setting of the temperature regulator can be taken from the description.
An oil sump heating (with selector switch above a certain size) has the task of evaporating
the cooling agent from the refrigeration machine oil in case of low surroundings
temperatures and during long standstill times of the refrigeration unit. If this does not
happen, then the compressor primes with liquid, which renders the compressor a write-off.
This immediately relinquishes the warranty.
Points to be observed after long periods of standsstill and low storage or surrounding
temperature:
- Machines without selector switch are to be connected to the mains supply 24 hours before
being putting into operation. During this time the oil sump heating runs and evaporates the
cooling agent away. Then after 24 hours have passed, the unit can be put into operation.
- Units with selector switch are to be connected to the mains supply 24 hours before being
putting into operation. As soon as the selector switch is switched on, the oil sump heating
runs and evaporates the cooling agent out. The refrigeration unit can still be prepared
further for putting into operation. It can only start run-up when the selector switch is
switched off again. The selector switch can be switched off after 24 hours.
Option: Mixing Valve Control
The option Mixing Valve Control is typically used in two cases:
1. To realize different temperature levels in chillers with more than one cooling circuit
2. To realize highly accurate control of outlet temperature in systems with more than one
cooling circuit, different media, that cannot be cooled via a joint evaporator, as well as
significant variations of required cooling capacity across the different cooling circuits
3.
The option Mixing Valve Control is realized using a central water reservoir, which is cooled
down to a temperature level below the lowest required outlet temperature. From this water
reservoir for each cooling circuit either a separate heat exchanger (water / outlet medium)
is supplied or water is directly taken with a separate consumer pump into a water outlet.
Temperature control is realized via electronic controllers and temperature sensors in the
outlet of the heat exchanger or in the outlet itself in case the heat exchanger is used. The
controller actuates a 3-way-mixing-valve in the water circuit. The mixing valve controls the
outlet medium temperature in the respective cooling circuit by adjusting the mixing ratio
between cold water and warm inlet water.

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In the case of pure water outlets without heat exchanger, for each cooling circuit a
dedicated consumer pump is required in addition to the main water pump. In this case the
secondary consumer pumps must be protected against dry-run. This protection is ensured
through complete opening of the mixer valves for 2 minutes and operating the main water
pump after starting-up the chiller. After 2 minutes the secondary consumer pumps are
switched on. This ensures sufficient water supply for the secondary consumper pump after
chiller start-up.
Option: Heating
The heating has the function of heating-up the medium to a certain temperature. Switching
over from cooling to heating and reverse takes place manually or automatically at the
regulator. The temperature is controlled by the regulator. For further details see Operating
Instructions- “Regulator”.
Option: User height
A solenoid valve in the return flow to the refrigeration unit and a non-return valve in the
refrigeration unit prevent discharges, that cooling medium runs back into the tank, when a
user stands higher than the refrigeration unit and when the pump does not run, i.e. when
the refrigeration unit is switched off.
Option: Winter pressure regulation
A pressure switch in the cooling agent circuit compulsively switches the ventilator off in
case of low surrounding temperatures under 8°C, until the system has enough higher
pressure, so that a circulation of cooling agent in the system is safeguarded.
Any other or excessive/outside the intended limits use thereof is regarded as non-designed
usage.
Option: Excessive flow valve
Instead of the constant bypass, which protects the pump from a customer-sided closed
slide valve and the cooling medium runs constantly between forward and reverse flow via
the bypass, there is a pressure-controlled bypass installed in some of the units, according
to the customer requirements. This only opens above a preset pressure and ensures that
the system is never exposed to a pressure higher than that preset.
Option: Level early-warning
The use of a second level indicator enables the issuance of an early-warning when the
level in the reservoir sinks and there is a danger of a shut-off via the normal level indicator.
This allows sufficient time to refill the vessels, without the low cooler level causing a switch-
off.
Option: Reference-driven regulation
In this case no fixed values are set at the regulator. The refrigeration unit orientates itself
around a reference value via a second sensor, for example at the surrounding temperature
or at the machine bed. The temperature of the refrigeration unit is then carried through
according to the change in the refence value. What is carried through can be limited to a
certain temperature range e.g. under 15 °C or on the other hand above 35°; here the
refrigeration unit can be set automatically to a fixed value which has to be entered.
Option: Dirt trap / Filter

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A dirt trap or medium filter is installed in the medium circuit which is to be cleaned regularly,
or exchanged depending on the degree of contamination of the medium.
Option: Automatic water feed
A floating switch connected to the customer-sided mains water supply automatically feeds
water into the medium tank as soon as the water level sinks.
Option: Flow monitor
In order to be able to protect the customer-sided machine or the customer´s application 2
monitoring systems are required. One is to monitor the temperature, which takes place
through the regulator and one to monitor the flow. If the customer does not monitor the
machine or his application himself, then a flow monitor can be fitted in the refrigeration unit
return flow, which issues a signal when there is no flow or less than a minimum threshold
amount. There are flow monitors with display and without display. The signal can serve as
a warning or activate a switch-off. Generally this option is combined with under & over-
temperature messages.
Option: Accumulative error message center
All error messages flow together into the error message center where a signal is given out.
The contact is potential-free. The accumumative error message center contains not only
the unit´s-own safety facilities but also the customer-relevant monitoring facilities. Details
can be sourced from the circuit diagram.
8.2 Safety facilities
The high pressure switch protects the refrigeration unit against unnecessary high operating
pressure in the cooling agent circuit. In case of malfunction the HP switch switches the
refrigeration unit off for a minimum of 4 minutes.
The mains isolation device serves the manual switching off of the unit in case of
emergency. In some cases the refrigeration unit has to be switched off by the
user/operator.
8.3 Monitoring facilities
Thelow pressure switch protects the refrigeration unit against unnecessary low operating
pressure in the cooling agent circuit. In case of malfunction the LP switch switches the
refrigeration unit off for a minimum of 4 minutes.
The winter pressure regulator prevents low pressure malfunctions in case of low
surrounding temperatures in the unit´s run-up phase until normal operating conditions have
been established.
The overheating protection at the compressor ensures that the refrigeration unit is switched
off in cases of increased motor current. The refrigeration unit switches on again after the
compressor has cooled down.
The overheating protection at the ventilator ensures that die refrigeration unit is switched off
in cases of increased motor current. The unit switches on again after cooling down.

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Circuit-breakers interrupt the current supply to the corresponding current consumer in
cases of increased motor current and short-circuits. Circuit-breakers can be waived,
depending on the plant & components and requirements of the standards.
A level indicator monitors the level of the user medium in the tank. In cases of insufficient
medium, the refrigeration unit is switched off until the level of medium has been restored.
In own-refrigeration units there is a current flow monitor to monitor the medium flow. If the
amount of flow falls below a certain value then the refrigeration unit is switched off.
The instrumentation unit monitors certain medium temperatures. Depending on the setting,
the refrigeration unit is switched off in cases of too-high or too-low values. For further
details see the circuit diagram.
9. Putting into Operation and Operating
A documented function, performance & safety acceptance procedure is carried out during
the course of manufacture.
The refrigeration unit is thoroughly inspected and tested in all its certified operative
elements.
9.1 Safety checks before putting into operation
A complete safety inspection is carried out on the unit before leaving the factory for
delivery.
Due to a change in the operational location, a safety, health and environment check on
location at the customer is recommended before putting into operation.
The room chosen for the aggregate has to have sufficient emergency exits. If this is not the
case, then a corresponding amount of room space according to DIN EN 378 has to be
available, so that in case of a cooling agent leakage there is no danger to health caused by
the leakage of cooling agent. This is best solved through consultation with the
manufacturer.
9.2 Safety checks during operation
The owner/operator is obliged to maintain documentation of safety-related inspections for
the refrigeration aggregate (available through the supplier). It is to be ensured that such
details are available to a technical expert in case of repairs and repeat inspections. A
suitable operating manual is available from the manufacturer.
In accordance with EN 378, regular inspections by suitable capable persons are prescribed
in order to maintain the minimum regulations regarding health & safety for the refrigeration
aggregate, the carrying out thereof being in the hands of the owner/operator. These can be
entered into the operating manual available from the manufacturer. The operating manual is
compiled in accordance with legal requirements.
9.3 Training and performance

02-2010 16
In order to ensure safe operation of the refrigeration unit and user, personnel are to be
retrained at regular intervals and on the basis of the operating manual. Included here are
the consequences for the user when the unit is switched off. A clearly readable & concise
notice is to be positioned near to the refrigeration unit. This is contained in the operating
manual available from the manufacturer.
9.4 Accident analyses
If there is an accident, which is caused by the direct or as a result of operating the
refrigeration unit, it is recommended to include the supplier into the analysis of the accident.
9.5 Management of changes in personnel
Here it is recommended to ensure that there is always a minimum amount of experience &
knowledge in the persons operating the machine. This is especially important in times of
vacations and illness, as well as for deputisatzions and outsourcings.
An on-site list of competent operators would serve this purpose.
9.6 Preparation for putting into operation
The cooling medium appliance is a compact unit which only needs to be connected to
electrical and hydraulic supplies, and can be in operation immediately after filling with
cooling medium. Take note of oil sump heating regulations.
The recommended medium level can be taken from the technical data.
Medium connections for the external circuit are to be laid out in accordance with the
available pump pressure and the amount of pressure loss to be expected. Take care to
observe nominal diameters. Take care to observe corrosion behaviour.
Make use of the circuit diagram to observe the prescribed electrical, as well as the signal-
technical connections.
Make sure that the unit cannot fall over.
Always adhere to the safety-related points.
9.7 Switching on- putting into operation
ATTENTION. Once the tanks have been filled, the pumps immediately start running when
switched on. Take note of oil sump heating regulations (10.1).
Pumps must never be allowed to run dry. Danger of fire.
After a brief period of operation, it should be checked whether the medium has to be topped
up. Once the operating temperature has been reached, all of the screw connections should
be checked again to ensure their tightness. The cooling cuts-in itself after 4 minutes. The
heating starts-up immediately upon being selected at the regulator.
10 Maintenance

02-2010 17
Place Symbol Description How can I avoid the danger?
Elektric
Danger through electric current
As with all electrical work, there is the
danger of electric shocks, short-
circuits etc.
All maintenance work, especially electrical work,
may only be carried out by suitably trained and
qualified persons
Isolate the refrigeration aggregate from the
mains supply before staring maintenance work
The main switch is to be fitted with a suitable
padlock
Complete aggregate Danger through materials and
other substances (or the other
components thereof)
All information about dangers has to be made
easily accessible to the operators and made
available nearby
Only suitable trained personnel
Complete aggregate Danger through internal/external
contact with liquids
Observance of the danger datasheets
Customer-sided filling of cooling medium is to be
documented
Cooling tank,
cooling system
Danger through burns
e.g. during maintenance, cleaning or
fault corrections
¾Wait till parts cool down to under 40°C
¾Use protective gloves:
Maintenance procedures are to be adhered to.
No technical changes to the refrigeration unit on the side of the customer are to be carried
out without agreement with the manufacturer.
Technical documentation for the machine is kept with the manufacturer for at least 10
years.
All changes to the documented technology are to be agreed upon with the manufacturer.
A change is only a change when it is not concerned with a homologous replacement within
the documented technology.
10.1 Maintenance for the operator
At regular intervals, the status of the cooling medium is to be checked and the medium is to
be topped up if so required.
It is recommended to check the tightness of all screw-connections in the circulations of
medium and cold water, resp. the oil circulation regularly 2 times a year.
The air intake of the pump is to be checked at regular weekly intervals for contamination i.e.
for free intake of the cooling air and cleaned if so required.
At certain prescribed time intervals, regular legally-binding leakage tests on the cooling
agent circuit have to be carried out by certified personnel. These persons have to present
their qualifications to the satisafction of the owner/operator. Test intervals are directly
dependant on the cooling agent amount and vary between yearly ( above 3kg i.e. 6kg in the
case of Hermetic systems), half-yearly (above 30kg) and quarter-yearly (above 300kg).
Tests are to be documented in one of the special manuals prepared for the unit. A suitable
operating manual is available from the manufacturer.

02-2010 18
Maintenance intervals for the air filter mats are dependant on the on-site condition of the
surroundings. These can be cleaned and are re-usable.
10.2 Notes on the replacement of components
Only original spare parts may be used, or only those expressly recommended by the
manufacturer.
Replacement of components is only permitted through the manufacturer or a specialist
company acting in the name of the manufacturer i.e. specialist persons known and
recommended by the manufacturer.
11 Warranty Provisions
Within the statutory warranty period, functional faults that are attributable to faulty
workmanship and/or material faults shall be rectified free of charge in the domestic market.
Abroad only the cost of material shall be borne.
All further claims, especially for consequential damage, shall be excluded
Damage and malfunctions brought about by improper handling and/or non-observance of
the operating instructions shall not fall under the warranty provisions.
The warranty shall expire if there has been any interference in the system structure or the
serial number on the item of equipment has been changed or has been rendered
unrecognisable.
The cooling equipment has been carefully checked and adjusted in the works. Should you
nevertheless have a complaint at any time, please confidently contact your contractual
partner. Please do not forget to let us have, for any possible queries, the name of the clerk
or technician responsible for the matter in hand.
To maintain your entitlement to any possible claims under the warranty please note the
following:
•Enclose with the letter an exact description of the defect.
•Enclose the evidence of purchase in the form of a copy of a delivery note or of an
invoice. Note on it the type and serial number of the item of equipment.
12 Taking out of Operation
Should the refrigeration unit be taken out of operation for longer periods of time, we
recommend switching the refrigeration unit free of voltage and removing the cooling
medium from the pumps, pipework and filter. Liability for frost damage or damage resulting
from the effects of algae will not be accepted under any situation whatsoever.
13 Breakdown: What is to be done if ...?
Should for some reason a fault/error appear during operation of the cooling equipment,
then the table which appears in the appendix will help to find a solution. In case of
uncertainty, it is always advisable to call a specialist.

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In case of emergency the Emergency telephone number 0049 (0) 170 582 64 84 is
available at all times.
14 Information about Spare Parts
See enclosed list.
15 Details about Disposal and Recycling
Environment-related requirements for the recycling, re-using and disposal of operational
materials and the refrigeration aggregate according to DIN EN 378 and ROHS Guidelines
are to be strictly adhered to. The owner/operator is solely responsible.
16 Rules for the Owner/Operator
16.1 Rules referring to the refrigeration unit
The owner/operator of the cooling equipment is obliged:
•to only allow suitably trained persons to work on the unit
•to ensure that the operating instructions are read and observed iun case of a change of
the operating personnel (especially safety instructions)
•to make sure the operating instructions are always at the workplace
•to ensure that the care & maintenance instructions are followed
•to make sure thaat the neccessary activities (e.g. maintenance) are only carried out by
suitable trained & qualified persons and groups of persons
•to train & qualify such persons and groups of persons if it is so required
•to ensure that the equipment is used only for the purpose it was designed and built for
The operators of refrigeration, air-conditioning & heating pump equipment are obliged by
law to carry out regular leakage inspections with certified personnel at certain regular
intervals. These persons have to present their qualifications to the satisafction of the
owner/operator. Test intervals are directly dependant on the cooling agent amount and
vary between yearly ( above 3kg i.e. 6kg in the case of Hermetic systems), half-yearly
(above 30kg) and quarter-yearly (above 300kg). Tests are to be documented in one of
the special manuals prepared for the unit. A suitable operating manual is available from
the manufacturer.
• It is recommended to periodically inspect and list all elements in the prescribed process-
related safety program from the owner operator. Updated information is to be entered
into this documentation.
16.2 Planning for emergencies and assignment
It is recommended to include the equipment into the emergency measures & control plan in
order to minimize potential consequences.

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16.3 Operational regulations and safety practices
Here there is a recommendation to include the operational regulations into the local
regulations.
Operating personnel must be able to understand the operational language.