IPG Photonics LC 340.01-A.3.5/6 User manual
Operating Manual Page 2
Operating manual LC 340.01-A.3.5/6 Current revision status: Apr 4, 2019
Notices
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in a retrieval system or adapt this publication, in any form, in any media or by any means,
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under applicable copyright laws. Permitted copies shall bear the same copyright and proprietary
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believes that the information provided is accurate and reliable, however IPG makes no warranty
or representation, express or implied regarding this document, including without limitation the
implied warranties of merchantability or fitness for a particular purpose. Further, IPG does not
assume responsibility for use of the information contained in this document or for any
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be liable for errors contained in this document or for incidental, consequential, indirect or
special damages in connection with the furnishing, performance or use of this material.
IPG grants no license, directly or indirectly under, any patent or other intellectual property rights
from use of the information provided herein.
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We have identified words that we consider as trademarks. Neither the presence nor absence of
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Preface
Please take time to read and understand this Service Manual and familiarize yourself with the
operating and maintenance instructions that we have compiled for you before you use the
product. We recommend that the operator read Chapter 2, Safety Instructions, prior to operating
the product.
This Service Manual should stay with the product to provide you and all future users and owners
of the product with important operating, safety and other information.
US Export Control Compliance
IPG’s policy and business code is to comply strictly with the U .S. export control laws.
Export and re-export of lasers manufactured by IPG are subject to the US Export Administration
Regulations administered by the Department of Commerce, Bureau of Industry and Security.
The applicable restrictions vary depending on the specific product involved, intended
application, the product destination and the intended user. In some cases, an individual
validated export license is required from the U S Department of Commerce prior to resale or re-
export of certain products. Please contact IPG, if you are uncertain about the obligations
imposed by US law.
Operating Manual Page 3
Operating manual LC 340.01-A.3.5/6 Current revision status: Apr 4, 2019
Current revision status: April 4, 2019
IPG Serial numbers:
Laser: ______________
Chiller: ______________
Operator details:
Inventory number:
Installation location:
Keep for future use
Index of contents:
1GENERAL INFORMATION 4
2SAFETY AND ACCIDENT PREVENTION 5
3TECHNICAL DATA 7
4TRANSPORT 12
5FIRST START-UP OF THE CHILLER 15
6PIPING AND INSTRMENTS DIAGRAM 21
7ADJUSTING AND MAINTENANCE WORK 28
8INTERRUPTION OF OPERATION 38
9ELECTRICAL DRAWING 53
General information Page 4
Operating manual LC 340.01-A.3.5/6 Current revision status: Apr 4, 2019
1 GENERAL INFORMATION
1.1 Introduction
Please take the time to read and understand the information presented in this manual.
By carefully reading the manual before starting up the chiller you will be better able to
ensure proper and safe operation of this equipment.
In case of problems, please disconnect the chiller and contact our service department.
Safety and accident Prevention Page 5
Operating manual LC 340.01-A.3.5/6 Current revision status: Apr 4, 2019
2 SAFETY AND ACCIDENT PREVENTION
2.1 General Instructions
This manual contains basic instructions that must be observed during initial operation
of the unit, as well as during regular operation and maintenance. This manual must
therefore be read by the installer and the operating personnel in charge prior to initial
operation. It must also be permanently available at the location where the unit is being
used.
All safety instructions including the instructions mentioned in other sections of this
manual must be observed. Non-observance of the safety instructions may cause
injuries, destroy the environment or damage the unit.
2.2 Personnel qualification and training
Operating, maintenance, inspection and installation personnel must be properly
qualified for their work. Scope of responsibility and supervision of personnel must be
defined and periodically reviewed by the facilities’ management.
2.3 Safe performance of work
The safety instructions mentioned in these operating instructions, including the existing
national regulations on accident prevention as well as any specific plant safety
instructions must be observed.
Protective guards that have been installed to prevent contact with moving parts may
not be removed when the unit is being operated. Lock-out / tag-out procedures must
be followed during maintenance and repair of this equipment. (For detailed information,
refer to your facilities’ procedures and the regulations of local authorities.)
2.4 Safety instructions on maintenance, inspection and installation work
As a basic rule, none of the cleaning or maintenance tasks may be performed until the
unit has come to a complete stop. The shutdown procedure described in the operating
instructions must be observed. As soon as this work has been completed, all the safety
devices and protective equipment must be mounted or installed according to their
proper function.
2.5 Arbitrary modification and production of spare parts
The unit may not be converted or modified without expressed permission and
agreement from the manufacturer. Only original spare parts and accessories accepted
by the manufacturer are authorized for replacement and repair. The use of any other
parts may cancel the manufacturer's liability for subsequent damages.
2.6 Non-Permissible operating methods
The operational safety of the delivered unit is guaranteed only if the unit is properly
used as intended in accordance with section 7.1. The limit values included in the
technical data (see item 2) must not be exceeded.
Safety and accident Prevention Page 6
Operating manual LC 340.01-A.3.5/6 Current revision status: Apr 4, 2019
2.7 Safety symbols
In this user manual you will find following safety symbols:
DANGER
DANGER:
Refers to a potential personal hazard. It requires a procedure that, if not
correctly followed, may result in death or extremely severe injury to you
and / or others. Do not proceed beyond a DANGER sign until you
completely understand and meet the required conditions.
WARNING
WARNING:
Refers to a potential personal hazard. It requires a procedure that, if not
correctly followed, may result in bodily harm to you and/or others. Do not
proceed beyond the WARNING sign until you completely understand and
meet the required conditions.
CAUTION
CAUTION:
Refers to a potential personal hazard, with lower risk. It requires a
procedure that, if not correctly followed, may result in bodily harm to you
and/or others. Do not proceed beyond the CAUTION sign until you
completely understand and meet the required conditions.
ADVICE:
Refers to a specific instruction for handling, operation, or maintenance of
the chiller.
Technical data Page 7
Operating manual LC 340.01-A.3.5/6 Current revision status: Apr 4, 2019
3 Technical Data
3.1 General data
Type: LC 340.01-A.3.5/6
Electric drawing: P35-001340
Mechanical drawing: P20-000165
3.2 Refrigerant circuit
Type of refrigerant: R407C
Refrigerant filling: kg 7.0
Maximum pressure: bar 28
3.3 Dimension and weight water module
Footprint:
Depth: mm 1093
Width: mm 815
Height: mm 1952
Additional depth electrical cabinet:
Depth: mm 211
Width: mm 500
Weight:
Without water filling: kg 480
With water filling: kg 600
3.4 Operating voltage 460 V / 3 Phase / 60 Hz
Design point:
Cooling capacity: kW 38.8
Heat load to the air: kW 52.2
Air inlet temperature: °C + 33
Air flow: m³/h 12000
Operating limits:
Max. air inlet temperature: °C + 40
Min. air inlet temperature: °C + 10
Min. water flow evaporator: l/min 44
Max. storage temperature: °C + 64
Min. storage temperature: °C - 40 (without water)
Electrical data:
Power consumption @ design point: kW 21.0 (without tank heaters)
Max. power consumption: kW 24.9
Connecting voltage: 460 V / 3 Ph / PE
Voltage tolerance: % +/- 10
Frequency: Hz 60
Control voltage: VDC 24
Technical data Page 8
Operating manual LC 340.01-A.3.5/6 Current revision status: Apr 4, 2019
Tap water circuit:
Cooling capacity: kW 37.8
Cooling water outlet temperature: °C + 21.0
Cooling water inlet temperature: °C + 28.6
Stability of cooling water temperature: °C +/- 1.0
Water content: Litre 120
Water flow: l/min 70
Water pressure: bar 4.5
DI-Water circuit:
Cooling capacity: kW 1
Cooling water outlet temperature: °C 30.0
Stability of cooling water temperature: °C +/- 0.5
Water content: Litre 25
Water flow: l/min 30
Water pressure: bar 4.0
3.5 Operating voltage 400 V / 3 Phase / 50 Hz
Design point:
Cooling capacity: kW 34
Heat load to the air: kW 42.5
Air inlet temperature: °C + 33
Air flow: m³/h 10000
Operating limits:
Max. air inlet temperature: °C + 40
Min. air inlet temperature: °C + 10
Min. water flow evaporator: l/min 35
Max. storage temperature: °C + 64
Min. storage temperature: °C - 40 (without water filling)
Electrical data:
Power consumption @ design point: kW 17.9 (without tank heaters)
Max. power consumption: kW 21.1
Connecting voltage: 400 V / 3 Ph / PE
Voltage tolerance: % +/- 10
Frequency: Hz 50
Control voltage: VDC 24
Tap water circuit:
Cooling capacity: kW 33
Cooling water outlet temperature: °C + 21.0
Cooling water inlet temperature: °C + 28.6
Stability of cooling water temperature: °C +/- 1.0
Water content: Litre 120
Water flow: l/min 70
Water pressure: bar 3.0
Transport Page 12
Operating manual LC 340.01-A.3.5/6 Current revision status: Apr 4, 2019
4 TRANSPORT
If the chiller has to be moved to another location, the water inside the tanks must be
drained. Take care during transportation, not to damage the chiller. If damage occurs,
the chiller must be checked by an expert before restarting.
WARNING
WARNING:
Cable angle if lifting by crane: < 60°
WARNING
WARNING:
Transport Page 14
Operating manual LC 340.01-A.3.5/6 Current revision status: Apr 4, 2019
ADVICE:
If the chiller has to be moved to another location, the water inside the
tanks must be drained.
If the route of transport is not frost-protected, the complete unit has to be
drained. We strongly recommend disassembling the DI-Cartridge as
completely draining of the cartridge is difficult. To start up the unit again,
please use a fresh DI-Cartridge.
First start-up of the chiller Page 15
Operating manual LC 340.01-A.3.5/6 Current revision status: Apr 4, 2019
5 FIRST START-UP OF THE CHILLER
5.1 Place of installation
The chiller has to be installed on a flat hard surface were the stability under load is
guaranteed. It’s not allowed to install the chiller at locations with risk of freezing
(ambient temperatures lower than 4°C)
DANGER
DANGER:
Refrigerant units have to be installed in a manner such that there is no
danger of damage due to in-plant traffic or transportation.
5.2 Wall distance
To ensure proper heat dissipation, the minimum distance from the air inlet grids to the
wall must be at least 800 mm.
5.3 Maintenance room
The free room above the chiller should be at least 1200 mm. Make sure that the
outgoing warm air cannot be re-circulated to the air inlet of the chiller.
5.4 Installation room according EN 378-1 tab. C.1
EN 378-1 defines the practical critical value for a refrigerant as the maximum
concentration, where direct actions to escape people out of the room are not
necessary.
According EN378-1 tab. C.1 the practical critical value for R407C is 0,31 kg/m³. The
minimum room size for areas with no entrance limitation is 20 m³.
DANGER
DANGER:
In case of damaging the refrigerant circuit, high pressured gas can
escape abruptly. The escaping gas will immediately cool down to -40°C.
The cold gas can cause frostbite to skin. The refrigerant gas is non-toxic.
DANGER
In case of a leakage please take care of following points:
- Please stop smoking in case of refrigerant gas leak. The gas will
pyrolyze in the presence of a lit cigarette and change into a toxic acid
that can cause a chemical burn
- Do not touch any escaping gas
- Please take care for a well air ventilation inside the room
- Turn the disconnector in OFF Position
- Inform an HVAC Technician
First start-up of the chiller Page 16
Operating manual LC 340.01-A.3.5/6 Current revision status: Apr 4, 2019
5.5 Connecting the chiller with the laser
The water connections are labelled as follows :
- Main Supply (Outlet chiller / Inlet laser)
- Optic Supply (Outlet chiller / Inlet optic)
- Main Return (Inlet chiller / Outlet laser)
- Optic Return (Inlet Chiller / Outlet optic)
Please use the provided hose pipes for connecting the laser with the chiller.
ADVICE:
It’s forbidden to use following materials for water piping:
- mild steel
- galvanized steel
We recommend to use following materials for water piping:
- Cooling circuit Laser: Copper or stainless steel
- Cooling circuit Optics: Stainless steel (1.4301)
Water pipes should be design as follows:
- Cooling circuit Laser: 8 m³/h @ pmax = 0,5 bar
- Cooling circuit Optics: 2 m³/h @ pmax = 0,5 bar
Figure 1: Water Connections
ADVICE:
Before starting up the chiller make sure, that:
a) Laser and optic cooling circuit are connected with the laser
b) All ball valves –laser and chiller –are open
Main Supply
Main Return
Optic Supply
Optic Return
Tank Drains
First start-up of the chiller Page 17
Operating manual LC 340.01-A.3.5/6 Current revision status: Apr 4, 2019
5.6 Charging of the cooling system
5.6.1 Cooling water specification
Use conditioned water with maximum conductivity of 50 µS/cm. The hardness of the
water should not exceed 0,25°dH.
5.6.2 Cooling water additives
A moderate chemical conditioning of the cooling water is important to protect the
system against corrosion, maintenance of heat transfer and minimizing of bacteria
inside the system. It’s an important requirement to guarantee the continued operation
of the laser and the chiller.
5.6.2.1 General
a) Intention of this specification is to describe the minimum effort for a preventative
chemical water conditioning.
b) The water treatment concept includes necessary chemicals, test methods, service
and equipment for operating and protecting the cooling water circuit.
c) The water treatment concept is designed for a maximum system volume of 200
liters.
d) Materials of the water system to be protected: Stainless steel, cooper and non-
ferrous metal.
5.6.2.2 Chemicals
Water treatment is only allowed in the laser circuit. In the optic circuit it’s not allowed to
use any chemicals.
All chemicals are complied with legal requirements:
a) These chemicals are not toxic for the employees if handled safely and reasonable
precautions are taken.
b) Effectiveness of the chemicals:
1) Corrosion Minimization to industry standard
2) Coating and fouling no
3) Biological fouling no visible fouling
no health risk
Plankton < 10³ CFU/ml
Pathogenic bacteria < 10 CFU/ml
Foray and barm < 10 CFU/ml
A water treatment kit is included with each chiller. Instructions for using the kit are
included in the kit. For additional kits, please contact IPG Service.
5.6.3 Start up laser circuit
When filling the tank with water use hose connections shown in the picture below. For
the first filling you need about 120 litres of water.
° dH - German
° e - England
° fH - France
ppm - USA
0,25° dH
0,31325° e
0,445° fH
4,45 ppm CaCO3
First start-up of the chiller Page 18
Operating manual LC 340.01-A.3.5/6 Current revision status: Apr 4, 2019
Figure 2: Filling the Tanks
ADVICE:
Make sure, that the temperature of the water does not exceed 30°C.
5.7 Choke valves
There is a choke valve installed on the water outlet of the optic pump. This valve allows
the water pressure to be adjusted in the optic circuit if necessary.
5.8 Motor protection switches
Before starting up the chiller, switch the motor-circuit switches in ON-Position. Check if
the adjusted currents are according to the currents given in the electric drawing.
Fill ports
Level indicators
First start-up of the chiller Page 19
Operating manual LC 340.01-A.3.5/6 Current revision status: Apr 4, 2019
5.9 Electrical connection
The chiller is completely wired and ready for operation. As soon as the laser has been
connected to a three-phase power system and the circuit breaker is switched to ON-
Position, the chiller will start operation when the following conditions are met:
- Fuse for chiller main power supply OK
- Fuse for chiller control voltage OK
- If activated, enabling of the chiller by the laser OK
- Chiller failure free
DANGER
DANGER:
The electrical connection has to be made by a skilled and authorized
worker according electric drawing.
ADVICE:
The chiller has to be connected with a clockwise rotating field. The
factory warranty is void if the electrical connections to the chiller are not
performed properly.
5.10 Checking the electrical rotating field
The pumps should now be running. As soon as the water temperature exceeds the set
point, the compressor will start.
Please look at the pump motors. You will find an arrow which indicates the proper
direction of rotation. Check, if the direction of the pump rotation is according to the
arrow.
Take a sheet of paper and put it in front of the air outlet grid. If the pump motor rotation
is correct, the paper sheet will flutter in the airflow.
The correct rotation of the compressor is checked by the control board. If the
compressor is rotating in the wrong direction, the control board will switch off the
chiller.
Checking rotation of the pump
First start-up of the chiller Page 20
Operating manual LC 340.01-A.3.5/6 Current revision status: Apr 4, 2019
Checking rotation of the fan –sheet of paper must be sucked
ADVICE:
Always ensure that the pumps turn in the proper direction. If direction of
rotation is wrong, the electrical connection needs to be corrected.
In case of wrong rotation, disconnect the chiller via main switch using
lock-out/tag-out procedures and unplug the chiller from voltage supply.
Phases L1 and L2 have to be reversed by and an authorized skilled
worker.
5.11 Ventilating the pump
Immersion pumps are self cooling. Ventilating the pump is not necessary.
ADVICE:
During the initial start up of the chiller, the pipes and the laser modules
will begin filling with water. This will cause the water level to fall.
Make sure, that water according item 5.6 is available so that you can
refill the tank when necessary.
The water level inside the tank will be controlled by level indicators. If the
water level is too low, the chiller will be switched off.
Table of contents
