KLH SC 2 Operational manual

14.12.2011 / 01.00
Am Waldrand 10
D-18209 Bad Doberan
Tel [phone]
Fax [phone]
E-mail: [e-mail]
Internet: http://www.klh-kaeltetechnik.de
Translation of the original Operating Manual
Operating Manual
Refrigerating Set
SC 2
KLH Kältetechnik GmbH
u n i v e r s a l c h i l l e r s
Read the operating manual before start working!
Keep the operating manual carefully for further usage!

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Ordering Information
Please indicate the title of the operating manual, your language, and the
date of issue.
KLH Kältetechnik GmbH
D-18209 Bad Doberan
Am Waldrand 10
Telefon [phone]
Telefax [phone]
E-mail [e-mail]
Internet http://www.klh-kaeltetechnik.de
This document has been established by the Technical Documentation
department of KLH Kältetechnik GmbH.
All rights in respect of this documentation, in particular the rights to
duplicate, distribute and translate it are reserved by KLH Kältetechnik
GmbH, including in the event of industrial property rights applications. No
part whatsoever of the documentation must be reproduced or processed,
duplicated or distributed with the use of electronic systems, in any form,
without the prior written consent of KLH Kältetechnik GmbH. Errors
excepted. Subject to technical modifications.
KLH Kältetechnik GmbH does not assume any liability for any mistakes in
this documentation. Any liability for any indirect and direct damage
occurring in connection with the delivery or the use of this documentation.
We guarantee on this cooling devices, filled with necessary quantity of
refrigerant by manufacturer, checked regarding tightness and examined
by a test run a respective guarantee according our contract declaration
assuming a professional use (skilled persons, keeping maintenance
intervals and operating the cooling device according to the pre-scribed
parameters).
Any claim expires in case the points of this operating manual are
neglected.
Guarantee/Warrenty

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Attention:
This equipment must run with water-glycol- solution as protection
against corrosion and frost protection (AFL)!
Ratio of mixture: 25 : 75 %
Serial No.:
Works No.:
Year of manufacture:
To be entered by the user:
Inventory number:
Installation side:
Edition:
12/2011
SC2.K1W.MT
Type:
50 Hz
60 Hz
Dual frequency
voltage
50Hz / 60Hz
X
X

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Table of contents
1. For your safety 5
1.1 Regulations 5
1.2 Signs and symbols 6
1.3 Security advice 7
1.4 Purpose 7
2. Description of the refrigerating set 8
2.1 Water-bearing equipment 8
2.1.1 Cooling circuit 9
2.2 Cooling equipment 10
2.2.1 SC 2 (water-cooled) 10
2.2 Electrical / Control equipment 11
2.4 Safety / Monitoring equipment 12
2.4.1 Safety devices 12
2.4.2 Monitoring devices 12
3. Technical data 13
4. Transport 14
4.1 Transport -Crane 14
4.1 Transport specification 14
5. Storage 14
6. Installation 15
6.1 Indoor installation 15
7. Connection of the refrigerating set 16
7.1 Connection –Water piping 16
7.2 Connection –Electrical system 16
7.2.1 Main feeding 16
7.2.2 Signal interface 16
8. Start-up 17
8.1 Start-up 17
8.1.1 Water Requirements 18
8.2 Placing out of service 18
8.3 Environment requirements 18
9. Operation 19
10. Maintenance 20
10.1 Repetition test 21
11. Fault / Trouble shooting 22
11.1 Malfunctions at the temperature controller 22
11.2 Displays 22
12. Dimension 23
13. Flow diagram 24
14. Spare parts list 25
15. Declaration of Conformity 26
16. Pump Characteristic Line 27
17. Description Temperature Controller 29
18. Abbreviated instructions 31
19. Electrical diagram 32
Table of contents

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1. For your safety
1.1 Regulations
The construction and design of the process coolers are in compliance with
the following national and international regulations.
EG-recommendation
- EC Machinery Directive 2006/42/EWG
- EC Low Voltage Directive 2006/95/EG
- EC EMC Directive 2004/108/EG
- EC Pressure Equipment-Directive 1997/23/EG
European Standards (EN)
EN 378 Refrigerantion plants and heat pumps
- Safety-relevant and environmental requirements
Part 1 Basic requirements, definitions,
classifications, and applications
Part 2 Design, manufacture, testing, marking, and
documentation
Part 3 Place of installation and protection of staff
Part 4 Operation, maintenance, repair, and recovery.
EN 60529 Degrees of protection provided by enclosures (IP)
EN 12100/T1/T2 Safety of machinery
-Basic terminology, methodology
- Technical guidelines and specifications
EN 394 Safety of machinery
- Minimum clearances to prevent crushing of body
parts
EN 60204 Electrical equipment of machinery
EN 61000-6-4 Electromagnetic compatibility –generic emission
standard
- Generic specification „ Noise transmission „
- residential, commercial, light industry and
industrial environment
EN 6100-6-1 Electromagnetic compatibility –generic immunity
EN 6100-6-2 standard
- Generic specification „ resistance to jamming „
- residential, commercial, light industry and
industrial environment
National Regulation
BGR 500 Operating method of work equipment,
Operating method of work equipment concerning
refrigeration plants, heat pumps and cooling
equipment
1 For your safety

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1.2 Signs and symbols
Throughout this operating manual, the information and notices
below are identified by graphical symbols:
Premonitorily symbols:
Danger !
Safety note pointing out an imminent danger. Failure to heed the
warning may result in serious bodily injury and even death.
Caution !
Safety note to indicate the presence of a potential hazard. Failure to
heed the safety notice may result in minor bodily injury or damage to
the equipment.
Advertently symbols:
Information !
This symbol identifies important information or a useful tip
concerning the application of the equipment.
Work procedure
This symbol identifies a work procedure.
Listing
This symbol identifies an enumeration or listing.
1 For your safety

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1.3 Security advice
For the installation and operation of the cooling machine, the following
regulations and safety notes have to be observed:
Any work on the process cooler may only be performed by
qualified personnel.
All relevant accident prevention regulations have to be observed.
The electrotechnical connections of the cooling machine must be
performed according to and conforming with all relevant VDE, EN
and IEC standards. Beyond that, the technical connection
requirements of the local electrical utility company have to be
observed.
Before attempting to carry out any work on the process cooler,
always disconnect the unit from the power supply.
. National standards applicable in the country where the unit is
installed must be complied with.
The safety equipment is not to be suspended.
Alterations of operation parameters of the cooling device are to be
carried out by authorised and introduced persons only.
The enclosed refrigeration cycle contains refrigerant and oil, which
must be disposed professionally (environmental care).
Cooling water additives have a caustic effect on the human skin
and eyes. When handling cooling water additives, wear eye-
protective glasses and safety gloves. Observe instructions on
product packing.
The operative range of the cooling machine has to perform
according to the determined technical data. (see chapter Technical
Data).
Watch out for any incompatibilities of materials in the entire water
circuit.
1.4 Purpose
Cooling machines are designed and constructed to keep the
temperature of a consumer medium constant within the determined
operation range by means of a cooling process (water at determined
quality or water with additives).
Operation has to be exclusively within the calculated load and operating
range.
1 For your safety

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2. Description
The cooler is of compact design. It consists of various functional sections including
the following subassemblies :
water-bearing equipment
cooling equipment
electrical / control equipment
safety / monitoring equipment
2.1 Water-bearing equipment
The heat generated at thecostumer machine is supplied to the cooler via water
circuit.
Inside the cooler, the circuit continues and equipped with the components
required.
5
PI
60
44
LC
TCI
LI
55
52
H
20l
Rp 1/2"
Rp 1/2"
40
KK
PB
A
Naming
Cooling water circuit
Evaporator
5
Pump
60
Tank
55
Float switch
Water level indicator
Discharge connection
Three-way valve
40
Pressure gauge
44
Temperature sensor
52
2 Description

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2 Description
2.1.1 Cooling circuit
Evaporator (5)
- Plate heat exchanger made of high-quality steel, copper soldered type.
Water tank (55)
- High-quality steel type, tank atmospheric open, covered, insulated for
condensation water, provided with discharge connection, water level
indicator, and built-in float switch for water level monitoring and filling.
Centrifugal pump (60)
- Multistage normal-suction horizontal high-pressure centrifugal pump of
block-unit design, made of plastics.
Pipe system
- Provided with fittings, madeof plastics hose (PUN-hose).
The heat generated at theload is supplied to the cooler via the cooling water
circuit. The cooling down of the water takes place in the evaporator (5) by way
of heat release. After cooling down, the cold water is supplied to thetank (55)
and is supplied back to the load via the pump (60) provided in the cooling
water circuit
(see also section 13- Flow diagram)

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2.2 Cooling equipment
2.2.1 SC 2 (water-cooled)
M
TC
4
33
6
8
20
20
20
PZH
94
220
IG1/2"
1
IG1/2"
10
KM
KW
5
The heat eliminated from the water circuits by means of an water-cooled cooling
machine. The cooling machine consist of a closed coolant circuit including all
components required. The coolant circuit circulates the coolant used as a working
medium.
Hermetic compressor (1)
- Hermetic compressor provided witha suction-gas cooled drive motor, motor protection by
means of an external monitoring module, oil-level glass, and external vibration-elastic
installation.
Water-cooled condenser (2/3)
- Plate heat exchanger, copper soldered type
Evaporator (5)
- Plate heat exchanger made of high-quality steel, copper soldered type
Pressure switch (HP)
- Pressure switch (High Pressure) (33)
Pipe system
- Closed pipe system madeof special copper tube, provided with collector (6) filter dryer (8)
and serviceconnections (20)
Inside theevaporator (5), the process heat generated is transfer from the water circuit to
the coolant circuit, at low evaporation temperature. It is then delivered to the condenser (2),
via compressor (1), together with thecoolant, in a gaseous condition. At the condenser, the
process heat is finally discharged to the water circuit.
The condenser pressure at the refrigeration circuit is constantly operated by the pressure
operated water valve.
Due to the heat release to the cooling water circuit, the coolant is liquefied and returned
to evaporator (5), via expansion valve (4).
Naming
Cooling equipment
circuit
Compressor
1
Condenser
2
Expansions valve
4
Evaporator
5
Tube expansion
6
Filter drier
8
Solenoid valve
10
Service connections
20
Pressure switch (HP)
33
Two-way valve
94
2 Description

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2.3 Electrical / Control equipment
The electro technical equipment of the cooler is installed in the switch
cabinet provided at the front end. The switch cabinet contains all
components required for automatic switching, control and regulating
operations.
Themain electric circuits are of fuseless design and are provided with
protectivemotor switches.
The necessary locks, compositions and monitorings are realized by
automatic control.
Composite Failure Report
The composite failure report is recording failures of the compressor,
pump(s) as well as high-pressure pressostat. This report is to be taken
potential-free from the terminals in the control cabinet (see also appendix
- Circuit-diagram).
The water outlet temperature in the cooling water circuit is regulated by a
temperature controller at a setpoint value by means of performance levels
at the cooling circuit . The outlet temperature changes as a function of the
momentary consumer power.
The current actual value of the water outlet temperature can be indicated
in the temperature controller.
Connection Cable With Harting Plug
The cooling device is delivered ready for use with Harting plug and
approx. 1,5m oil-flex cable.
Remote Control 24V
The cooling device is switched ON or OFF by means of a 24V remote
control. The 24V signal it to be connected according to the circuit diagram
2 Description

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2.4 Safety / Monitoring equipment
2.4.1 Safety devices
High-pressure switch (HP) (33)
The high-pressure switch is for protecting the coolant circuit against
exceeding the maximum admissible operating pressure.
In caseof fault, thepressure switch(HP) switches off the cooling machine
and indicates thefault messages at fault alarm.
(see also Section 11.1 - Fault/Trouble shooting)
The cooling machine may be switched on again only after the pressure has
been reduced to the preset pressure and after using the outside positioned
reset button.
2.4.2 Monitoring device
Float switch
Thefloat switches provided in tank (55) are for monitoring the water filling
level. A minimum admissible filling level, which must by no means be
allowed to fall further, guarantees a constant water discharge temperature.
If the water level continues to fall and reaches theminimum limit value, the
cooling machine and the pump will be switched off (dry run protection).
(see also Section 11.1 - Fault/Trouble shooting).
Thefloat switch is mounted into the tank and it is accessiblefrom the service
side.
Level indicator
Thelevel indicators provided with MIN and MAX markings show the water
filling level insidethe tanks. The level indicators are provided on the service
side of the cooler are clearly visible from outside the tank.
Motor protective switch –compressor and pump
In caseof increased motor current and/or short circuit, the protectivemotor
switch is released, and the power supply is interrupted. The fault is
displayed at the control panel (see also Section 11.1 - Fault/Trouble shooting
and Electrical diagram). After the fault has been eliminated, theprotective
motor switch shall be switched on manually.
The protective motor switch is provided inside the switch cabinet.
Temperature controller
The temperature controller controls automatically the water and refrigerant
circuits. At the temperature controller the water temperature as well as
warnings and faults are displayed. The controller is integrated at the
cabinet door.
2 Description
Reset button
Pressure switch (HP)
Temperature controller

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3. Technical data
General
SC 2
General dimensions
l x b x h
450 x 445 x 365
Weight net (unloaded weight)
kg
55
Weight gross (operating weight)
kg
75
Versions
Air temperature
Min.
Max.
3 x 400V/50Hz indoor installation
°C
+10
+43
3 x 460V/60Hz indoor installation
°C
+10
+43
Wasser equipment
Cooling agent
water/AFL mixture of 75:25%
Water temperature
°C
2 (2...14)
Max. Control deviation
K
± 1
Water flow rate
m³/h
0,3
Free pump pressure
bar
ca. 3
Tank volume
l
20
Pump 400V/3/50Hz
type
Y/YS-2051
Pump 460V/3/60Hz
Typ
Water connection OUT
mm
1 x Rp ½“
Water connection IN
mm
1 x Rp ½“
Cooling equipment
Cooling capacity
kW
1,8
At ambient temperature // Cooling water
temperature
°C
20
Refrigerant
R407C
Frequency
Hz
50/60
60
Refrigerant weight
kg
0,5
Air volume flow
m³/h
-
Sound pressure level in 1m distance,
semi sound field without reflection (service side)
dB(A)
45
Max. heat transfer on air or cooling water
kW
47
Cool water flow
m³/h
0,7
Min. pressure difference cooling water IN OUT
bar
2
Max. pressure IN
bar
2,5
Water connection OUT cooling water
Rp ½“
Water connection IN cooling water
Rp ½“
Electro technical data
Operating voltage
V/Ph/Hz
400V/3/50-60Hz
Voltage tolerance
V
24VDC
Control voltage
%
± 10
Power input
kW
4,7/5,4
Operating current total
A
8,3/7,4
Max. starting current
A
21,6
Apparent power
kVA
5,75/5,12
Recommended protection (power switch)
A
16
3 Technical data

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4 Transport / 5 Storage
4. Transport
The cooler shall be transported in an upright condition, without
water filling, on a pallet. In-house handling shall be performed by
means of fork lift trucks or platform lift trucks or crane.
To prevent any distortions of the lower frame, the cooler must
be lowered onto a level surface.
4.1 Transport - Crane
For the transport of the cooler with a crane, screw bore holes
are provided in the lower frame enabling a 2- or 4-point sling
load arrangement to be established.
Use spreader!
To avoid damages of the frame use spreader acc. DIN 15401
and sling band acc. DIN EN 1492-1!
Load Suspension Devices
Lifting rope assemblies acc. DIN 3088 or lifting chain
assemblies acc. DIN 5687/5688 fulfil the requirement of a sling
with equal rope or chain length.
Rope Inclination Angle
Do not exceed a 45° rope inclination angle from the
perpendicular.
Lifting speed
Keep the lifting speed to a minimum (v lift < 10 m/min,
precision lifting, jerk-free lifting)
4.1 Transport specification
- Weight (see Section, 3. Technical data)
- General dimensions (see Technical data)
- Ambient temperature –20°C to +70°C
At ambient temperatures <0°C, it is necessary to completely
drain the water circuits, pumps, water filters and tanks via
draining hoses.
(see also Section 8.2 - Placing out of service).
5. Storage
The cooler shall be stored on a smooth and horizontal surface
having the load-bearing capacity required.
The admissible storage temperature is –20°C to +70°C
provided that all water circuits, pumps, water filters and tanks
are completely drained.
(see section 8.2 - Placing out of service).

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6. Installation
The transportation packing is to be removed.
6.1 Indoor installation
The cooler shall be installed in a frost-free room, on a smooth and
horizontal surface having theload-bearing capacity required. The cooler
has to be installed as plug-in boxat the customer.
Foundationfixing or usevibration absorbers arenot necessarily required.
Observe minimum distances required for maintenance and
servicing operations!
For cooler installation in basement or upper floors of buildings
without adequate emergency exits, standard EN 378 stipulates
requirements to be complied with in terms of protection of staff at
the place of installation.
In view of the existing refrigerant filling volume of the cooler, the
minimum room size must not be less than 15 m³ to make sure that
refrigerant discharge (leakage) in case of damage and subsequent
oxygen displacement has no adverse effects on the health of staff.
The equipment of the cooler with origin parts ensures a safe
operation of the installation.
Modification and changing of origin parts have to be ensue only
after consultation with the manufacturer!
1 Operation side and service side
2 Connection side
6 Installation
1
2
1
Double sided bores with internal thread for
screw in of the lifting eyes at costumer side

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7 Connection
7. Connection
Please note Security advice (see also chapter 1.3)
Check cleanliness inside the hose pipes prior to assembly!
7.1 Connection water-piping
Connect thehose pipes of the external water circuits to the
corresponding connection nozzles provided at the cooler.
The nominal widths of the pipes for the external water circuit are to be
defined on the basis of the available pump pressure and the expected
pressure drop in the consumer circuit.
Water outlet - water fore run and water inlet - water returnflow of the
cooling device are to be mounted onto the pre-set water connections.
The water pipes may be of rigid or flexibletype. The corrosion behaviour
of thematerials used by the consumer must be compatible with the water
in order to prevent any damage.
When the piping system is installed by the customer at the
installation site, care must be taken that the pipe system is free of
contamination (if required, the pipes should be flushed before the
cooling device is connected).
1 Cooling water –inlet 6 °C (KW-inlet)
2 Cooling water –outlet 6 °C (KW-outlet)
3Cooling circuit –inlet 18 °C (KK-inlet)
4 Cooling circuit –outlett 18 °C (KK-outlet)
7.2 Connection electrical system
Please note Security advice (see also 1.3)
Voltage
400V/50Hz-460V/60Hz
7.2.1 Main Feeding and Signal interface
Take out of the cooler the connection cable formain feeding and remote
control.
Complete electro technical connection in accordance with circuit diagram
(see also circuit diagram).
1
3
2
4
1
3
2
4

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8. Start-up
Please note Security advice (see also chapter 1.3)
At storage temperature < 10°C allow for an appropriate
acclimatization period before turning the cooler on ( formation of
condensation water!).
The cooler is designed for the exclusive cooling of water.
Fill water circuits with water according to specifications only .
8.1 Start-up
Disconnect mains voltage and remotecontrol by Harting plug
Put protectivemotor switch in therespective –0–positions,
Remove covering panels and tank covers,
Fill tanks with water up to theMAX marking provided at the level indicators,
Vent pumps via vent screw provided at pump housing,
Connect mains voltage by Harting plug,
Turn on remote control from machine at customer side (please refer to
machine operators manual),
Put automatic fuse and protective motor switch for pumps and fans
in therespective –1–position (see also circuit diagram),
Switching on pumps remote control from themachine,
Check direction of rotation of pumps.
In case of incorrect direction of rotation of pumps, render cooler
electrically dead and reverse the 2 (two) phases of the main
connection cable. Dry-run of pump to be avoided, therefore filling up
first before starting pump. In case of closed system type, the
additional venting system provided at the customer’s site must be
actuated
When starting up pump(s) or consumer, the water level in the tank falls
down. Check water filling level at thelevel indicator. Refill water if required.
Check the water circuit visually as to tightness,
Check required water volume flow by means of the pressure gauge and
the pump performance chart (see also appendix - Pump Characteristic
Line)
Mount tank covers and covering panels,
Put protective motor switch for compressors in the respective –1–
position,
Acknowledge all fault and warning messages at the control unit,
Check rated value setting of thethermostatic controller.
The cooler is ready to work, the thermostatic controller take over the
control of all water circuits temperature.
8 Start-up

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8.1.1 Water Requirements
Is there consist a danger of water contamination during operation a
strainer may have to be installed.
8.2 Placing out of service
Please note Security advice (see also chapter 1.3)
Disconnect process cooler from power supply.
Drain water circuits completely empty.
For this are to use the water level indicator as tank drain. Fold level
indicator from the holder.
Ensure freezing protection (consult the manufacturer).
8.3 Environmental requirements
When repairing or placing the process cooler out of service, the
environment-relevant requirements regarding recovery, recycling and
disposal of service products/fuels and components according to DIN
EN 378 are to be complied with.
The responsibility for the proper disposal of operating supplies and
plant components which are no longer usable shall be assumed by the
user of the cooler.
The disposal of water containing additives shall be performed in
consultation with the regionally competent authorities.
8 Start-up
This equipment must run with water-glycol- solution as protection
against corrosion and frost protection (AFL)!
Ratio of mixture: 25 : 75 %
Water level indicator /tank drain

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9Operation
9. Operation
Notice unconditional the safety information and
regulation (see chapter 1.3)!
The cooling device is switched on by means of the mains
voltage and remote control at customer side. The cooler
is switched off by means of the opposed manner as
EMERGENCY STOP circuit.
The cooling device is ready for operation and the
temperature controller takes over the control of the water
outlet temperature.
The set point is adjusted on the temperature controller
(see also appendix - Description Of Temperature
Controller).
(Adjustable value setpoint tw2=6 °C)
In systems equipped with a tank (Single or dual -circuit
system) a fault indicator light signals when there is a
water shortage. This indicator light is extinguished
automatically when the water has been topped up to the
MAX.-mark.

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10. Maintenance
M A I N T E N A N C E I N T E R V A L S
Maintenance position
Interval
Activities
General
3 month
Visual inspection (see also chapter 10.1)
Check refrigeration unit for contamination, stains
of water and oil.
Water cycle
Water filter (option)
to be prescribed by the user
clean water filter
Water filling level
2 month
Inspection of the water is limited to water filling
level. degree of water contamination and quality
of water.
If there is an excessive contamination in thetank,
the latter must be cleaned. In case of
longstanding operation, a water treatment is
recommended.
The water treatment by the customer has to
insure, that depositing and corrosion is
avoided under extreme conditions, too.
Please note Security advice (see also chapter 1.3)
According to DIN EN 378 every refrigeration plant must be subjected to
preventive maintenance at least once a year.
A visual inspection of the cooling device is to be performed at regular
intervals.
10 Maintenance