Comet XRC-4523-OW User manual

Industrial X-Ray
Cooler Manual XRC-4523-OW
4500 watt oil to water cooler

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COMET AG
Herrengasse 10
3175 Flamatt
Switzerland
Phone: [phone]
Fax: [phone]
E-Mail: [email protected]
Internet: www.comet-xray.com
Protection Notice
Dissemination as well as copying of this document, utilization or posting of its contents is not permitted
unless formally granted. Violations entail claims for compensation. All copyrights, including rights due
to patent grant or registration of a utility model or design, are reserved.
All product names used in this manual are trademarks of the corresponding manufacturers.
Technical modifications are subject to change.

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Contents
1. ABOUT THIS MANUAL ...............................................................................6
1.1. Explanation of symbols and signs .............................................................6
1.1.1. Safety symbols .......................................................................................................................................6
1.1.2. Warning instructions...............................................................................................................................6
1.1.3. Text designations....................................................................................................................................7
1.2. Illustrations...................................................................................................8
1.3. Terms of warranty........................................................................................8
1.4. Contact information.....................................................................................9
2. SAFETY......................................................................................................10
2.1. Hints for the safe operation.......................................................................10
2.1.1. Prevent hazards....................................................................................................................................10
2.1.2. Hints regarding the electrical equipment...............................................................................................10
2.1.3. Inadmissible operating conditions.........................................................................................................11
2.2. Responsibilities of the unit operator........................................................11
2.2.1. Planning and monitoring the safety measures......................................................................................11
2.2.2. Minimizing the risk of injury...................................................................................................................12
2.3. Personnel requirements............................................................................12
2.3.1. Qualifications........................................................................................................................................12
2.3.2. User groups..........................................................................................................................................12
2.3.3. Specialized knowledge.........................................................................................................................13
2.3.4. Exclusion criteria...................................................................................................................................13
2.4. Personal protective gear ...........................................................................14
2.5. Safety and signaling equipment included in the unit..............................14
2.6. Guards.........................................................................................................14
2.7. Caution label...............................................................................................15
2.8. In case of accidents...................................................................................15
2.9. Environmental issues................................................................................15
3. PRODUCT IDENTIFICATION ....................................................................16
3.1. Unit specifications .....................................................................................16
3.2. Identification plate .....................................................................................16
4. UNIT DESCRIPTION..................................................................................17
4.1. Intended use...............................................................................................17
4.2. Non-conformity with the intended use.....................................................17
4.3. Predictable errors during operation.........................................................17

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4.4. Unit components........................................................................................18
4.4.1. Cooling circuit.......................................................................................................................................18
4.5. Technical specifications............................................................................18
5. TRANSPORT, PACKING AND STORAGE ...............................................20
5.1. Safety ..........................................................................................................20
5.2. Checking the delivery condition...............................................................20
5.3. Symbols on the packaging........................................................................21
5.4. Packing .......................................................................................................21
5.5. Manual handling.........................................................................................21
5.6. Handling with industrial truck...................................................................22
5.7. Storing the unit...........................................................................................22
5.8. Preparing the unit for the further transport .............................................23
6. INSTALLATION AND COMMISSIONING..................................................24
6.1. Requirements concerning the installation location................................24
6.1.1. Installation location...............................................................................................................................24
6.1.2. Environmental conditions......................................................................................................................24
6.1.3. Infrastructure ........................................................................................................................................24
6.1.4. Placing the unit.....................................................................................................................................24
6.2. Using the unit for the first time.................................................................25
6.3. Connecting the unit electrically................................................................25
6.4. Putting the unit into operation..................................................................26
7. CONTROLLING THE UNIT........................................................................28
7.1. Switching on the unit.................................................................................28
7.2. Switching off the unit.................................................................................28
7.3. Settings.......................................................................................................28
7.3.1. Flow switch...........................................................................................................................................28
7.3.2. Pressure relief valve.............................................................................................................................29
7.3.3. Cooling water controller........................................................................................................................30
7.3.4. Thermostat ...........................................................................................................................................31
8. DISRUPTIONS ...........................................................................................32
8.1. Safety ..........................................................................................................32
8.2. Disruption in operation..............................................................................32
8.2.1. Troubleshooting....................................................................................................................................33
9. MAINTENANCE AND CLEANING.............................................................34

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9.1. Safety ..........................................................................................................34
9.2. Maintenance schedule...............................................................................36
9.3. Preparing the unit for maintenance..........................................................37
9.4. Disconnecting the coolant hoses.............................................................37
9.5. Disconnecting the cooling water hoses...................................................38
9.6. Connecting the coolant hoses..................................................................39
9.7. Connecting the cooling water hoses........................................................40
9.8. Draining the coolant ..................................................................................41
9.9. Adding coolant...........................................................................................41
9.10.Removing and mounting the unit cover...................................................42
9.11.Cleaning the casing ...................................................................................43
10. REPAIR...................................................................................................43
10.1.Safety ..........................................................................................................43
10.2.Repair procedures .....................................................................................43
11. DECOMMISSIONING AND DISPOSAL .................................................44
11.1.Temporary placing out of operation.........................................................44
11.2.Returning the unit to service after decommissioning.............................44
11.3.Final decommissioning, disposal.............................................................44
11.4.Disposal of operating materials................................................................45
11.5.Return of the unit to COMET.....................................................................45
12. WEAR PARTS AND SPARE PARTS.....................................................46
13. ADDENDUM............................................................................................47
13.1.Performance diagram ................................................................................47
13.2.Flow chart...................................................................................................48
13.3.Wiring diagram...........................................................................................49
13.4.Dimension drawing....................................................................................51

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1. About this manual
This document is manual for the cooling unit XRC-4523-OW. It is based on international safety regula-
tions.
This operating manual addresses the needs of the user of the unit. Its intention is to allow the safe
operation of the unit. Thus, it should be read carefully and be kept in a space accessible for the users
of the unit at any time.
All chapters of this operating manual can be read independently and thus can be used for look-up
purposes.
1.1. Explanation of symbols and signs
1.1.1.Safety symbols
The safety symbols used in this operating manual are indicated below. The main reason for their use
is to point the reader to the safety instruction given in the text field beside.
Symbol
Meaning
Warning with respect to general danger or damage to property.
Warning with respect to electrical hazard.
Table 1: Warning signs
Symbol
Meaning
This symbol indicates the requirement of disconnecting from mains.
This symbol indicates the requirement of wearing protective footwear.
This symbol indicates the requirement of wearing protective gloves.
This symbol indicates the requirement of wearing protective eyewear.
Table 2: Mandatory action signs
1.1.2.Warning instructions
In this operating manual concrete warning instructions are given in order to point out unavoidable re-
sidual risks when operating the unit. These risks include hazard for
Human beings
The unit and other equipment
The environment
Warning instructions in this operating manual are identified using symbols. The warning instructions
are introduced using signal words which express the scale of the hazard.
Always comply with the warning instructions and act cautiously in order to avoid accidents, injuries to
persons and damage to property.

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DANGER
DANGER
Reference to immediate danger to human health.
Failure to comply with this warning instruction will result in severe irreparable injury
and even death.
WARNING
WARNING
Reference to recognizable hazard to human health.
Failure to comply with this warning instruction may result in severe irreparable injury
and even death.
CAUTION
CAUTION
Reference to recognizable hazard to human health.
Failure to comply with this warning instruction may result in slight to medium injury.
NOTE
Reference to a material hazard.
Failure to comply with this warning instruction may result in material damage.
Structure of the warning instructions
The following information builds the warning instructions:
Warning symbol
Signal word
Type and source of the hazard
Causing
Measure(s) to avoid the hazard
Example:
WARNING
WARNING
Risk of burning and/or scalding due to possibly hot coolant.
Coolant can reach high temperatures during operation and cause burns or scalding
in the case of contact.
Check whether the coolant is hot before handling it. If necessary, let it cool
down to the ambient temperature, that there is no more risk of burns or scald-
ing.
Important information and tips concerning operation of the unit
This symbol is used to highlight passages with important information and tips concerning opera-
tion of the unit.
1.1.3.Text designations
Text mark-ups

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Text that appears in bold refers to emphases and subheadings.
Step-by-step instructions
Step-by-step instructions have the following structure:
Objective for action
Requirement(s)
Tools and material required
Procedure
Prompt to take action (indicated by a 1)
Prompt to take action (indicated by a 2)
(Preliminary) result
Prompt to take action (indicated by a 3)
Prompt to take action (indicated by a n)
Result
1.2. Illustrations
Illustrations in this operating manual are provided for general understanding and can be different from
the actual version of the unit.
1.3. Terms of warranty
General sale and delivery terms of COMET apply. The buyer accepts these terms, at the latest when
signing the contract of purchase.
The particular terms of warranty and duration of warranty of the unit in question can be taken from the
contract documents as well as from the order confirmation.
Warranty claims and liability are excluded in case of one of the following situations:
Use of the unit in an unintended way
Inaccurate installation, putting into service, operation, repair or maintenance of the unit by
people that are not fully authorized
Use of the unit despite of defect, wrongly implemented or non-functional safety devices or
protective gear
Unauthorized or forbidden modifications by the user concerning the electrical equipment
of the unit
Unauthorized or forbidden modifications by the user concerning the mechanical structure
of the unit
Unauthorized or forbidden modifications by the user concerning the operating parameters
Use of unauthorized tools
Use of unauthorized operating supplies
Exceedance of mandatory maintenance intervals
Cases of disaster caused by foreign matter influence or act of nature beyond control

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NOTE
Any form of unintended use of the unit and any structural change caused by the user without prior
authorization in written form by COMET will lead to the termination of warranty as well the termina-
tion of the declaration of conformation and will free COMET from product liability. This concern inclu-
des safety devices as well.
In case of authorized changes or when adding optional equipment it is the sole responsibility of the
customer to assure the accurate implementation of the safety devices required.
1.4. Contact information
If you have questions with respect to this unit please use the contact information given below. Always
communicate the following:
Your name and address
Name of contact at your address
Product data as on identification plate: Type of unit, serial number, article number and
year of manufacture
Company contact:
Mail:
COMET AG
Herrengasse 10
CH-3175 Flamatt
Internet:
http://www.comet-xray.com
E-Mail:
[email protected]
Phone:
[phone]
Fax:
[phone]

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2. Safety
This chapter provides an overview of all important safety aspects for optimal protection of personnel as
well as safe and trouble-free operation.
Disregarding this operating manual and warning instructions specified therein may result in considera-
ble danger.
2.1. Hints for the safe operation
Conduct inspections on a regular time base. This will ensure that the appropriate measures will
actually be carried out.
The unit is operational save. It was built according to the existing state of technology.
Despite this the unit could cause hazards, if it is
used in a way it was not intended for
used improperly
operated under unsuitable conditions
2.1.1.Prevent hazards
Hazards can be prevented by safety-conscious and anticipatory behavior of staff.
Everybody working with the unit should keep the following in mind:
Make this operating manual available for everybody at the operational location of the unit
in a complete and perfectly readable form!
Use the unit exclusively for what it was intended!
The unit must be operational and error free. Check the condition of the unit before work-
ing with it and within a regular time frame!
Make sure that nobody can injure themselves by any part of the unit!
Any disruption or recognizable change concerning the unit should be reported to the per-
son responsible.
Stick to the accident prevention regulations as well as any regional regulations!
Use personal protection equipment!
2.1.2.Hints regarding the electrical equipment
DANGER
DANGER
Electrical danger!
Work on electrical installations may be carried out by trained and authorized electri-
cians only.
Switch off the unit before starting your work.
Disconnect the unit from mains by pulling the mains plug.
Secure the unit against being switched on again.
Verify that the unit is dead.
Carry out earthing and short circuiting.
Keep unauthorized persons away from the working area.
When working on electrical installations the following principles should be observed: