Hypertherm Koolant Koolers N-Series User manual

Koolant Koolers N-Series
Plasma Cutter Chiller
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OriginalInstructions800.968.5665|dimplexthermal.com 
User Manual
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Hypertherm, Inc. Part Number: 810540

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ATTENTION
Thismanualprovidestheuser,installerand
maintenancetechnicianthetechnicalinformationfor
installation,operation,androutinemaintenanceto
ensuresmoothandlong‐lastingoperationofthe
CHILLER.Thismanualhasbeenwrittenwithgeneral
guidelinesandspecificationsforthisplatformofchillers.
AlwaysrefertoyourCHILLER’sspecificdrawingsthat
haveshippedwiththeunit.Whencontactingthe
factoryforserviceorreplacementpartsreferenceyour
CHILLER’sserialandmodelnumbers.Thesecanbe
foundonthedatatagontheCHILLERoronthe
Datapackinformationthatshippedwiththeunit.
InformationSubjecttoChange
Whileeveryefforthasbeenmadetoensurethe
accuracyandcompletenessoftheinformation
presentedinthisdocument,DimplexThermalSolutions
assumesnoresponsibilityanddisclaimsallliabilityfor
damagesresultingfromtheuseofthisinformationor
foranyerrorsoromissions.
RegisterYourChiller
SeeinstructionsinAppendixEforregisteringyourchiller
online.Registrationisimportanttoensureaccessibility
totheDimplexThermalSolutionsglobalservicenetwork
andmaximizeyourwarrantycoverage.
Hypertherm, Inc. Part Number: 810540

TableofContents
i
TableofContents
ListofTables...............................................................................................................................................................v
1Specifications.....................................................................................................................................................6
2ImportantSafetyInstructions...........................................................................................................................7
3MachineLabelDefinitions.................................................................................................................................8
4Introduction.......................................................................................................................................................9
4.1RatedCapacity.........................................................................................................................................10
5SitePlanning....................................................................................................................................................12
5.1OverallDimensions..................................................................................................................................12
5.2LocationConsiderations..........................................................................................................................12
5.2.1EnvironmentalRequirements..........................................................................................................12
5.2.2Elevation..........................................................................................................................................13
5.2.3ElectricalEnclosureClearance.........................................................................................................13
5.2.4ServiceDoorClearance....................................................................................................................13
5.2.5AirIntakeandExhaustClearance....................................................................................................14
5.2.6ProximitytothePlasmaCuttingSystem.........................................................................................15
6Installation.......................................................................................................................................................15
6.1CheckingforShippingDamage................................................................................................................15
6.2Transportation.........................................................................................................................................15
6.3UnpackingfromtheCrate.......................................................................................................................16
6.4InternalAccess.........................................................................................................................................17
6.4.1FromtheAirIntake/FilterSide........................................................................................................17
6.4.2FromtheDoorSide..........................................................................................................................17
6.5ElectricalSupplyMains............................................................................................................................18
6.5.1MainsPowerRequirements............................................................................................................18
6.5.2MainsConnectivity..........................................................................................................................19
6.6InterlockConnections..............................................................................................................................22
6.7EthernetConnection...............................................................................................................................22
6.8PlumbingConnections.............................................................................................................................22
6.9CoolantReservoirFilling..........................................................................................................................23
6.10RefrigerantFilling....................................................................................................................................24
6.11InstallationChecklist................................................................................................................................24
7Operation.........................................................................................................................................................25
Hypertherm, Inc. Part Number: 810540

TableofContents
ii
7.1Pre‐Startup..............................................................................................................................................25
7.1.1Power‐up.........................................................................................................................................25
7.1.2FaultCheck......................................................................................................................................25
7.1.3SettingtheLinePowerFrequency...................................................................................................25
7.1.4CompressorWarm‐up.....................................................................................................................25
7.2InitialStartup...........................................................................................................................................26
7.2.1LocalModeStart‐up........................................................................................................................26
7.2.2RemoteMode..................................................................................................................................27
7.3Shutdown.................................................................................................................................................27
7.4Service.....................................................................................................................................................28
8Controller.........................................................................................................................................................29
8.1Navigation................................................................................................................................................29
8.2Alarms......................................................................................................................................................30
8.2.1TurningofftheBuzzer.....................................................................................................................30
8.2.2ViewingActiveAlarms.....................................................................................................................30
8.2.3ResettingAlarms..............................................................................................................................30
8.3MainMenu..............................................................................................................................................31
8.4ChillerStatus............................................................................................................................................31
8.5Monitoring...............................................................................................................................................33
8.6Devices.....................................................................................................................................................36
8.7Setpoints..................................................................................................................................................40
8.8Maintenance&Service...........................................................................................................................41
9Troubleshooting..............................................................................................................................................44
9.1AlarmList.................................................................................................................................................44
9.2InlineHeaterTemperatureLimitSwitch.................................................................................................48
9.3RefrigerationHighPressureSwitch.........................................................................................................48
10Maintenance................................................................................................................................................49
10.1SuggestedMaintenanceChecklist...........................................................................................................49
10.2ReplacingtheParticulateFilterCartridge...............................................................................................50
11ChillerDataTag............................................................................................................................................53
12FactoryContact...........................................................................................................................................54
12.1ServiceSupportTeam..............................................................................................................................54
12.2PartsDepartment....................................................................................................................................54
Hypertherm, Inc. Part Number: 810540

TableofContents
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13Revisions......................................................................................................................................................55
AppendixA(P&IDiagrams).....................................................................................................................................56
RefrigerationSchematic......................................................................................................................................56
PlumbingSchematic............................................................................................................................................57
AppendixB(ElectricalSchematics).........................................................................................................................58
PowerPage..........................................................................................................................................................58
PLC.......................................................................................................................................................................59
I/OModule..........................................................................................................................................................60
Logic.....................................................................................................................................................................61
ElectricalPanel....................................................................................................................................................62
ElectricalBOM.....................................................................................................................................................63
AppendixC(DefaultControllerSettings)................................................................................................................64
ProgramSettings.................................................................................................................................................64
SensorCalibration...............................................................................................................................................65
AlarmSettings.....................................................................................................................................................66
I/OModule..........................................................................................................................................................67
AppendixD(Warranty)............................................................................................................................................68
WarrantyCoverage..............................................................................................................................................68
GeneralWarrantyProcedures.............................................................................................................................69
WarrantyWork................................................................................................................................................69
WarrantyParts................................................................................................................................................69
AppendixE(DeclarationofConformity).................................................................................................................70
AppendixF(ChillerRegistration).............................................................................................................................74
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Hypertherm, Inc. Part Number: 810540

ListofFigures
iv
ListofFigures
Figure1:PlasmaCutterChiller(ElectricalEnclosureSide).....................................................................................10
Figure2:PlasmaCutterChiller(PlumbingI/OSide)................................................................................................11
Figure3:ChillerOverallDimensions.......................................................................................................................12
Figure4:ChillerAirIntakeandDischargeClearances............................................................................................14
Figure5:CratedChiller...........................................................................................................................................16
Figure6:ChillerInternalAccess..............................................................................................................................18
Figure7:ChillerElectricalEnclosureSide...............................................................................................................20
Figure8:ElectricalEnclosureBottomView(InsideChiller)...................................................................................20
Figure9:ElectricalPanel(Simplified).....................................................................................................................21
Figure10:ChillerPlumbing&ElectricalConnectivity............................................................................................23
Figure11:Chiller’sController.................................................................................................................................29
Figure12:ControllerMainMenu...........................................................................................................................31
Figure13:Monitoring,Temperatures....................................................................................................................33
Figure14:Monitoring,SystemStatus....................................................................................................................33
Figure15:Monitoring,Condenser&SuctionData................................................................................................33
Figure16:Monitoring,ProcessFluidCircuit..........................................................................................................34
Figure17:Monitoring,RecirculationCircuit..........................................................................................................34
Figure18:Monitoring,FilterStatus........................................................................................................................34
Figure19:Monitoring,AmbientTemperature.......................................................................................................35
Figure20:Devices...................................................................................................................................................36
Figure21:Devices,CompressorStatus..................................................................................................................36
Figure22:Devices,ProcessPumpStatus...............................................................................................................36
Figure23:Devices,RecirculationPumpStatus......................................................................................................37
Figure24:Devices,HeaterStatus...........................................................................................................................37
Figure25:Devices,FanStatus................................................................................................................................37
Figure26:Devices,MotorizedHotGas,LOPProtection........................................................................................38
Figure27:Devices,ExpansionValve1....................................................................................................................38
Figure28:Devices,ExpansionValve2....................................................................................................................38
Figure29:Devices,I/OModule..............................................................................................................................39
Figure30:Setpoints,Temperature.........................................................................................................................40
Figure31:Setpoints,PlasmasystemOutletFlow..................................................................................................40
Figure32:Setpoints,StandbyMode......................................................................................................................40
Figure33:Maintenance&Service,MainMenu.....................................................................................................41
Figure34:Maintenance&Service,About..............................................................................................................41
Figure35:Maintenance&Service,ContactService...............................................................................................41
Figure36:Maintenance&Service,ContactParts..................................................................................................42
Figure37:Maintenance&Service,CompressorandFanRunTime......................................................................42
Figure38:Maintenance&Service,PumpRunTime..............................................................................................42
Figure39:Maintenance&Service,HeaterandUnitRunTime..............................................................................43
Figure40:Maintenance&Service,AlarmLogExport............................................................................................43
Figure41:ChillerInternalComponents(AirFilter/IntakeSide).............................................................................51
Figure42:ChillerInternalComponents(PanelSide)..............................................................................................52
Figure43:ChillerDataTag......................................................................................................................................53
Hypertherm, Inc. Part Number: 810540

ListofFigures
v
ListofTables
Table1:ChillerSpecifications...................................................................................................................................6
Table2:MachineLabelDefinitions..........................................................................................................................8
Table3:KoolantKoolersPlasmaCutterChillerModelInformation......................................................................10
Table4:ChillerOperatingEnvironmentalRequirements.......................................................................................12
Table5:ChillerElectricalSupplyPowerRequirements..........................................................................................18
Table6:ChillerPlumbingConnections....................................................................................................................22
Table7:RecommendedCompressorWarm‐upTime.............................................................................................26
Table8:ChillerStatuses.........................................................................................................................................31
Table9:AlarmList...................................................................................................................................................44
Table10:ManualRevisions....................................................................................................................................55
Table11:ElectricalPanelBillofMaterials.............................................................................................................63
Table12:DefaultProgramSettings........................................................................................................................64
Table13:DefaultSensorCalibrationSettings........................................................................................................65
Table14:DefaultAlarmSettings............................................................................................................................66
Table15:I/OModuleDefaultSettings...................................................................................................................67
Hypertherm, Inc. Part Number: 810540

Specifications‐RatedCapacity
6
1Specifications
Table1:ChillerSpecifications
Criterion50Hz60Hz
Electrical
Inputpower380‐415V±10%,
3Phase
460‐480V±10%,
3Phase
FLA23A
MCA26A
MOPD40A
SSCR12kA(RMSsymmetrical)
Refrigeration
RefrigerantR‐407C
RefrigerantOilPolyvinylEther(PVE)
NominalRefrigerantCharge7lbs.(3.2kg)
NumberofCompressors1
CompressorMotorPower,each5hp(3.73kW)
CoolingCapacity
148,794Btu/hr
(14.3kW)
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ProcessCoolingCircuit
NumberofProcessPumps1
ProcessPumpMotorPower1hp(0.75kW)
NominalProcessPumpFlowRate1.3GPM(4.92LPM)
PressureReliefValveSetting190‐230PSI(13.1‐15.9bar)
NominalProcessCoolantSupplyTemperature59°F(15°C)
RecirculationCircuit
NumberofRecirculationPumps1
RecirculationPumpMotorPower0.34hp(0.25kW)0.58hp(0.43kW)
RecirculationPumpFlowRate13.8GPM(52.2LPM)16.2GPM(61.3LPM)
Physical
Dimensions
[D]49.4”(1,254mm)
[H]80.2”(2,038mm)
[W]37.8”(960mm)
Uncratedweight830lb.(376.5kg)
Cratedweight1,042lb.(473kg)
1At59°F(15.0°C)leavingfluidtemperatureand104°F(40.0°C)ambienttemperaturecondition.

Hypertherm, Inc. Part Number: 810540

 ImportantSafetyInstructions‐RatedCapacity 
7
2ImportantSafetyInstructions
Thismanualcontainsimportantsafetyinstructionsthatshouldbefollowedduringtheinstallationand
maintenanceofthe5TonKoolantKoolersPlasmaCutterChiller.Readthismanualthoroughlybefore
attemptingtoinstalloroperatethisunit.Failuretofollowtheinstructionsinthisdocumentmaydamagethe
equipment,causehazardousconditionsandvoidthewarranty.
Onlyproperlytrainedandqualifiedpersonnelshouldmove,install,operateorservicethisequipment.
Adheretoallwarnings,cautionsandsafetyinstructionsontheunitandinthismanualwheninstalling,operating
ormaintainingtheunit.Followalloperatinganduserinstructions.

WARNING
Thisunitmaypresentarcflashandelectricshockhazardsthatcouldcauseinjuryordeath.
Openalllocalelectricpowerdisconnectswitchesandwearprotectiveequipmentbeforeworking
withinthechillercabinet.
Earthgroundtounitmustbeprovided,perNEC,CECandlocalcodes,asapplicable.Adheretoall
otherlocalcodesasapplicable.
TurningtheON/OFFswitchtotheOFFpositiondoesnotisolatepowerfromtheunit.Theonlywayto
isolateallpowerfromtheunitistoturnthechiller’smaincircuitbreakerdisconnecttoitsOFF
position.Thisshouldonlybeperformedwhenintendingtoservicetheunit.


WARNING
Thechillerhasautomaticallystarting,high‐speedfans.Openallelectricpowerdisconnectswitches
beforeworkingintheunit.Contactwithfanswhenthechillerispoweredcancauseinjuryordeath.
Donotoperatethisunitwithanycabinetpanelsorairfiltersremoved.


CAUTION
Fanandpumpmotors,compressors,andrefrigerationcomponentscanbecomeextremelyhotduring
operation.Allowsufficienttimeforthemtocoolbeforeworkingwithintheunit.Wearprotective
glovesandarmprotectionwhenworkingonornearhotcomponents.
OnlyHVAC/Rqualifiedtechniciansshouldbeworkingonrefrigerationcomponents.


CAUTION
Improperinstallation,applicationandservicepracticescanresultinwaterleakagefromtheunit,
causingdamagetopropertydamageandlossofdatacenterequipment.
Donotlocateunitdirectlyaboveanyequipmentthatcouldsustainwaterdamage.


CAUTION
Improperstoragecancausedamagetotheunit.
Keeptheunitupright,indoorsandprotectedfromdampness,freezingtemperaturesandcontact
damage.

Hypertherm, Inc. Part Number: 810540

 MachineLabelDefinitions‐RatedCapacity 
8
3MachineLabelDefinitions

Table2:MachineLabelDefinitions
SymbolDescription SymbolDescription

AlarmLight

TankDrain

EmergencyStop

FluidInlet

Local/Off/Remote

FluidOutlet

TankLevelHigh
TankFill,NoTap
Water,Referto
Manual

TankLevelLow

ElectricalShock
Hazard,DoNot
TurnOff,LockOut
TagOut,Referto
Manual

DoNoRemove
Guards

California
Proposition65
Warning

CautionFanStarts
Automatically

Network
Connection

Hypertherm, Inc. Part Number: 810540

Introduction‐RatedCapacity
9
4Introduction
TheKoolantKoolersIndoorIndustrialProcessChillerisasingle‐circuit,singlereservoirchillerdesignedto
supplycoolanttotheHyperthermPlasmaCuttingSystem.Heatremovalfromtheplasmacuttingsystemtothe
chillerisfacilitatedthroughheatexchangersinaclosed‐loopfashionusinganair‐cooledrefrigerationcircuit.
Thechilleriscapableofsteadilysupplyingcoolantwithtighttemperaturetolerancesoveravaryinganddynamic
rangeofcoolingcapacityrequirements.Thechillerfeatures:
ScrollCompressor
Provenreliability
Lownoise
Processcircuitregenerativeturbinepump
Highlyreliable(noslidingcomponents)
Optimizedforhighpressurecircuits
Recirculationcircuitcentrifugalpump
Moderatesthereturncoolanttemperaturefromtheplasmacutterpriortopassingthroughthe
brazedplateheatexchanger
Highlyreliable(noslidingcomponents)
Variablespeedcondenserfan
Minimizesacousticnoise
Improvedenergyefficiency
Managesrefrigerationsuctionpressureunderlowambienttemperatures
Continuouscoolantreservoirlevelsensing
Provideslowreservoirwarnings
Preventspumpsfromrunningdry
Process&recirculationflowsensing
Protectspumpsfromrunningdry
Supportspropersettingofthrottlingandreliefvalves
Refrigerationpressureandtemperaturesensors
Enablethesuctionanddischargeconditionsoftherefrigerationcircuittobemonitoredbythe
controller
Enablethecontrollertocalculatesuperheatandsubcoolingconditionstosupportremote
troubleshooting
Remotemonitoringandcontrolcapabilities
Plug‐and‐playcommunicationviaModbusEthernet
Built‐inwebserverfordataloggingandremotemonitoring

Hypertherm, Inc. Part Number: 810540

 Introduction‐RatedCapacity 
10
4.1 RatedCapacity
Table3:KoolantKoolersPlasmaCutterChillerModelInformation
DTSPart
NumberModelDescriptionMaximumHeatLoad
801880NVI‐5001‐CE‐MC‐M5TonPlasmaCutterChiller*69,800Btu/hr(20.5kW)
802092NVI‐5001‐NR‐CE‐MC‐M5TonPlasmaCutterChillerw/oRefrigerant*69,800Btu/hr(20.5kW)
*Ratedcapacitybasedon59°F(15°C)leavingfluidtemperatureand75°F(23.9°C)ambient.

Figure1:PlasmaCutterChiller(ElectricalEnclosureSide)
ELECTRICAL
ENCLOSURE
CONDENSERFAN
DOORPANELAIRINTAKE
FILTER
Hypertherm, Inc. Part Number: 810540

 Introduction‐RatedCapacity 
11

Figure2:PlasmaCutterChiller(PlumbingI/OSide)

PLUMBINGI/O
INTERLOCK
CONNECTIONS
ETHERNET
CONNECTIONS
TANKDRAIN
TANKLEVEL
SIGHTGLASS
Hypertherm, Inc. Part Number: 810540

 SitePlanning‐OverallDimensions 
12
5SitePlanning
5.1 OverallDimensions

Figure3:ChillerOverallDimensions
5.2 LocationConsiderations
5.2.1 EnvironmentalRequirements
Table4definestheenvironmentalrequirementsforproperchilleroperation.Forconsiderationofspecial
applicationsthatdonotadheretotherequirementsinthetablebelowcontactGlenDimplexThermalSolutions
(GDTS)engineeringforreview.
Table4:ChillerOperatingEnvironmentalRequirements
CriterionValue
LocationIndoorsonly
MinimumTemperature14°F(‐10°C)
MaximumTemperature104°F(40°C)
MinimumRelativeHumidity10%
MaximumRelativeHumidity90%
MinimumAltitudeAtsealevel
MaximumAltitude8,000ft(2,4384m)abovesealevel

Hypertherm, Inc. Part Number: 810540

 SitePlanning‐LocationConsiderations 
13
5.2.2 Elevation
Thechillersareintendedtobeinstalledonthesamefloorlevelastheplasmacuttingsystem.Installationona
mezzanineisacceptableaslongastherequirementsidentifiedinSection5.2.3throughSection5.2.6aremet.

CAUTION
Thechillersarenotequippedwithananti‐backflowdevice.Installingthechilleratalower
elevationthantheplasmacuttingsystemorinstallingoverheadplumbingbetweenthechiller
andtheplasmacuttingsystemcancausethechillerfluidreservoirtooverflow.
5.2.3 ElectricalEnclosureClearance
OSHAandtheNECbothmandateaminimumclearanceof36inchesonelectricalenclosuredoorsoflessthan
600voltsandlessthan65,000symmetricalfaultamps.

5.2.4 ServiceDoorClearance
Thechillersareequippedwithremovableservicedoorsononesideofthemachine.Atleast3feetofclearance
isrequiredbetweenthechillerandanyotherobstructionstoenableserviceaccesstotheinternalcomponents
ofthechiller.

36
in
Hypertherm, Inc. Part Number: 810540

 SitePlanning‐LocationConsiderations 
14
5.2.5 AirIntakeandExhaustClearance
5.2.5.1 SupplyClearance
Thechillersareequippedwithremovableintakeairfiltersononesideofthemachine.Caremustbetakento
ensurethatadequateclearanceisprovidedtoensurefreshairisabletoentertheintakeairfilters.Atleast3
feetofclearanceisrequiredbetweentheintakeairfilterandanyobstructions.Iftheintakeairfilterisfacinga
facilitywallatleast6feetofclearanceisrequired.
5.2.5.2 ExhaustClearance
Atleast8feetofverticalclearanceisrequiredfromthetopoftheexhaustfanstothebuildingceilingorany
otherobstructionsthatcouldimpedeexhaustairflow.

CAUTION
Installingthechillerinabuildingcornershouldbeavoided.Placingthechillerinacorner
preventsproperdissipationofthehotexhaustairandcausestheexhaustairtore‐circulate
intothechillerairintake.Thisleadstohighrefrigerationheadpressure,poorchiller
performance,andover‐heatingtheexhaustfanmotors.

CAUTION
Thechillercondenserfansarenotdesignedforducting.Ductingcreatesexcessive
backpressureonthefansandcancausethefanmotorstooverheat.

Figure4:ChillerAirIntakeandDischargeClearances


Hypertherm, Inc. Part Number: 810540

 Installation‐CheckingforShippingDamage 
15
5.2.6 ProximitytothePlasmaCuttingSystem
TheHyperthermHPR800XDplasmacuttingsystemissuppliedwithastandardhosekitforconnectingthe
processcoolingcircuitwaterfromthechillertotheplasmacuttingsystem.Thechillerlocationmustbeclose
enoughtotheplasmacuttingsystemtoenableconnectivitywiththestandardhosekit.

CAUTION
Exceedingthestandardhoselengthscancauseexcessivepressuredropthroughplumbing
systemsthatleadstochillerflowfaultsand/orprematurechillerpumpfailures.
6Installation
6.1 CheckingforShippingDamage
Upondeliveryofthechilleralwaysverifythattheshipmentmatchesthebilloflading.
Inspectthechillerimmediatelyforsignsofshippingdamagebothvisibleandconcealed.Damagedcrating
indicateslikelydamagetothechillerandmayrequiretheremovalofthepaneland/orairfilter(s)forfurther
inspection.Refertosection6.4InternalAccesstoremovethepanelorairfilter(s)ofthechiller.
AnydamagemustbereportedtotheshippingcarrierandacopyofthedamageclaimsubmittedtoGDTSoryour
salesrepresentative.
6.2 Transportation
Thechillerisshippedinacratewithprotectivepackingandwrappingthatshouldremaininplaceuntiltheunitis
transportedtoitsfinalinstallationlocation.Itisrecommendedthatthechiller(cratedoruncrated)bemoved
withaforklift.

WARNING
Thechillerisheavyandthereisriskoftiltingorfallingwhenmoved.Transportationofthe
chillermustonlybeperformedbytrainedandqualifiedpersonnelusingappropriate
equipment.
Ensurethatthechillerissecurelypositioned(tinesofforkliftspreadasfaraspermittedalong
thechiller’slongedgeandextendthoroughlythroughtheoppositeliftingface)beforemoving
thechiller.
Improperhandlingorinsecureliftingofthechillerduringtransportationcancauseittotipand
fallleadingtoinjuryordeath.

WARNING
Thechillerisonlyintendedtobeliftedfromthesides(filterordoor).Liftingthechillerfrom
theends(ElectricalenclosureorplumbingI/O)cancauseittotipandfallleadingtoinjuryor
death.



Hypertherm, Inc. Part Number: 810540

 Installation‐UnpackingfromtheCrate 
16
6.3 UnpackingfromtheCrate
Thechillerissecuredtotheskidatthebottomofthecratewithmetalshippingbrackets.Thecrateisheld
togetherwithwoodscrews.Toremovethechillerfromitscrate:
1. Movethecratedchillerascloseaspracticaltoitsinstallationlocation.
2. StartdisassemblyofthecratebyremovingtheT25Torx®headwoodscrewssecuringthetoppanelof
thecrate.
3. ContinuedisassemblybyremovingtheT25Torx®headwoodscrewsholdingthetwoshortpanelsofthe
crate.Thiswillallowaccesstotheinternalbracing.
4. RemovetheT25Torx®headwoodscrewssecuringtheinternalbracingtothetwolongsides.
5. Removethe3/8‐16boltssecuringtheshippingbracketstothebaseofthechillerusinga9/16”wrench.
6. Cuttheshippingbagthatthechillerwasplacedin.
7. Cutorunwraptheplasticshrink‐wrapfromtheunit.
8. Removethedesiccantbaglocatedintheebox,alongwiththedesiccantbaglocatedinsidethechiller,
referencingsection6.4onhowtogaininternalaccesstothechiller.
9. Removethelagboltssecuringtheshippingbracketstotheskidusinga1/2”wrench.
10. Removetheshippingbrackets.
11. Useaforklifttoliftthechilleruntilitscastersclearthetopboardsoftheskid.
12. Pulltheskidfromunderthechiller.
13. Lowerthechillerontothefloor.
14. Movethechillerintoitsfinalinstallationposition.
15. Lockthecasters.

Figure5:CratedChiller
Hypertherm, Inc. Part Number: 810540

 Installation‐InternalAccess 
17
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WARNING
Useextremecarewhenliftingthechillerasitistopheavy.Tippingoverthechillerduring
liftingcouldcausesevereinjuryordeath.Theforkliftforksshouldbespreadasfarapartas
possiblewhenpositionedunderthechiller.Liftingthechillershouldonlybeperformedbya
trainedforkliftoperator.

6.4 InternalAccess
Toaccessthechiller’sinternalcomponents(refertoFigure6:ChillerInternalAccess):
6.4.1 FromtheAirIntake/FilterSide
1. Useaslottedscrewdrivertoturnthequarter‐turnAirFilterLatchesabovetheAirFilters
counterclockwise.
2. GentlylifttheAirFilterupwardbyitsmeshandthenpulloutwardtoremovethefilter.
3. Formoreaccess:
a. Useaslottedscrewdrivertoturnthequarter‐turnSideBlockerLatchcounterclockwise.
b. LifttheSideBlockerstoreleasetheguidefingersfromthebaseandremovethemfromthe
machine.
c. Useaslottedscrewdrivertoturnthequarter‐turnUpperBlockerLatchlocatedontheright
counterclockwiseandtheUpperBlockerLatchontheleftclockwise.
d. GrabthebottomoftheUpperBlockerandpulloutwardtoreleasethefingersatthetopof
theUpperBlockerfromthemachinesidesandremovetheUpperBlocker.
4. Reinstallintheoppositeorderwhenaccessisnolongerrequired.

NOTICE
Theairfilter(s)havealabelthatindicatetheproperinstallationorientation.Thefilter(s)should
beinstalledwiththislabelfacingupwardsandwiththeintakesideofairoutsidethechiller.
6.4.2 FromtheDoorSide
1. Useaslottedscrewdrivertoturnthequarter‐turnDoorLatchcounterclockwise.
2. GentlylifttheDoorupwardusingtheDoorHandleandpulltheDooroutwardtoremovefromthe
machine.
3. Formoreaccess:
a. Useaslottedscrewdrivertoturnthequarter‐turnUpperBlockerLatchlocatedontheright
counterclockwiseandtheUpperBlockerLatchontheleftclockwise.
b. GrabthebottomoftheUpperBlockerandpulloutwardtoreleasethefingersatthetopof
theUpperBlockerfromthemachinesidesandremovetheUpperBlocker.
4. Reinstallintheoppositeorderwhenaccessisnolongerrequired.

NOTICE
Thechillermusthaveallairfiltersandpanelsproperlyandsecurelyinstalledwhenoperating.
Failuretodosocanresultinrefrigerationcircuitfaultsthatwillinterruptcoolingtotheplasma
cuttingsystem.

Hypertherm, Inc. Part Number: 810540

 Installation‐ElectricalSupplyMains 
18
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Figure6:ChillerInternalAccess
6.5 ElectricalSupplyMains
6.5.1 MainsPowerRequirements
EnsurethatthesupplypowerissufficienttomeetthechillerpowerrequirementsdefinedinTable5and
conformstoalllocalandnationalelectricalcodes:
Table5:ChillerElectricalSupplyPowerRequirements
Criterion50Hz60Hz
Voltage[V]380‐415V±10%460‐480V±10%
Phase3
FLA[A]23
MCA[A]26
MOPD[A]40
SCCR[kA]12
Note:Thisinformationcanalsobefoundonthechiller’sdatatag,
locatedonthefrontoftheelectricalenclosure(refertoFigure7,
datatagnotshown).
 
AIRFILTERLATCHDOORLATCH
UPPERBLOCKER
2XUPPERBLOCKERLATCH
2XSIDEBLOCKERLATCH
DOORHANDLE
AIRFILTER
SIDEBLOCKERS
DOOR
Hypertherm, Inc. Part Number: 810540