Laird WL3004 Installation instructions

WL3004 Liquid to Air Cooling System
Specification and User Manual Version 1.2

2
Laird Thermal Systems.
Prumyslová 497
462 11 Liberec
Czech Republic
Phone: [phone]
www.lairdthermal.com
Any information furnished by Laird and its agents, whether in specifications, data sheets, product catalogues or otherwise, i
s believed to be (but is not warranted as being) accurate and
reliable, is provided for information only and does not form part of any contract with Laird. All specifications are subject
to change without notice. Laird assumes no responsibility and
disclaims all liability for losses or damages resulting from u
se of or reliance on this information. All Laird products are sold subject to the Laird Terms and Conditions of sale (including Laird’s
limited warranty) in effect from time to time, a copy of which will be furnished upon request.
© Copyright 2020 Laird T
hermal Systems GmbH. All Rights Reserved. Laird, Laird Technologies, Laird Thermal Systems, the Laird Logo, and other word marks and logos are trademarks or
registered trademarks of Laird Limited or an affiliate company thereof. Other product or service na
mes may be the property of third parties. Nothing herein provides a license under any Laird
or any third party intellectual property rights.

3
Table of Contents
Revision History.................................................................................................................................... 5
1. About this Manual ......................................................................................................................... 6
Terms of Guarantee ............................................................................................................................ 6
Contact Information............................................................................................................................. 7
2. Product Identification ................................................................................................................... 8
Unit Specifications............................................................................................................................... 8
Identification Plate ............................................................................................................................... 8
3. Safety Regulations........................................................................................................................ 9
Hazard classes.................................................................................................................................... 9
Safety Symbols ................................................................................................................................... 9
Hints for Safe Operation.................................................................................................................... 10
Prevent Hazards ............................................................................................................................... 10
Hints Regarding the Electrical Equipment ........................................................................................ 10
Environmental Issues........................................................................................................................ 11
Safety Equipment.............................................................................................................................. 11
Safety and Signaling Equipment included in the Unit ....................................................................... 11
Guards............................................................................................................................................... 12
Caution Labels .................................................................................................................................. 12
In Case of Accidents ......................................................................................................................... 13
4. Product Description.................................................................................................................... 14
Intended Use..................................................................................................................................... 14
Use not in Conformance with the Intended Use ...............................................................................14
Unit Components .............................................................................................................................. 15
Cooling Circuit................................................................................................................................... 15
Specifications .................................................................................................................................... 16
Setting-up Requirements .................................................................................................................. 17
Infrastructure ..................................................................................................................................... 17
5. Transport...................................................................................................................................... 18
Safety Indications for Transportation and Setting-up........................................................................ 18
Transportation of the Unit.................................................................................................................. 18
Unpacking ......................................................................................................................................... 18
6. Initial Operation........................................................................................................................... 19
Safety Indications Related to Initial Operation .................................................................................. 19
Setting to Work.................................................................................................................................. 19
Electrical Connections....................................................................................................................... 21
Daily Start-up .................................................................................................................................... 22
Setting to work after Storage............................................................................................................. 22
7. Controlling the Unit..................................................................................................................... 23
Safety Indications for Controlling the Unit......................................................................................... 23
Switching on the Unit ........................................................................................................................ 23

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Switching off the Unit ........................................................................................................................ 23
Settings ............................................................................................................................................. 24
8. Disruptions .................................................................................................................................. 26
Disruption in Operation ..................................................................................................................... 26
Trouble Shooting............................................................................................................................... 26
9. Maintenance and Cleaning............................................................................................................. 27
Maintenance Schedule...................................................................................................................... 27
Cleaning of Heat Exchanger ............................................................................................................. 27
Refilling of Coolant ............................................................................................................................ 27
Cleaning of Strainer .......................................................................................................................... 28
Cleaning of Unit Casing .................................................................................................................... 29
10. Repair ....................................................................................................................................... 30
11. Dismounting, Disposal, Storage............................................................................................ 31
Temporary Placing out of Operation ................................................................................................. 31
Re-packaging of the unit ................................................................................................................... 32
Storing the Unit ................................................................................................................................. 32
Disposal............................................................................................................................................. 32
Disposal of Operating Materials ........................................................................................................ 32
Return of the unit to Laird Thermal Systems .................................................................................... 32
12. Wear Parts and Spare Parts ................................................................................................... 33
Addendum............................................................................................................................................ 35
Flow scheme ..................................................................................................................................... 35
Wiring diagram .................................................................................................................................. 36

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Revision History
REV
DATE
DESCRIPTION
NAME
Page
1.2 04/22/20 Document template updated to LTS format, spelling errors
corrected.
Maria
Mjalgard
1.1
03/22/19
Set point of temperature switch changed from 55°C to
45°C.
Jonathan
Knutsson
16
1.0 07/31/19 Henrik Olsson

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1. About this Manual
This document is the English translation of the original Operation Manual in German language for the
Water-Air Cooling Unit WL 3004 (called unit in the following). It is based on German safety
regulations. In your country other regulations may apply.
This Operational 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 Operation Manual can be read independently and thus can be used for look-up
purposes.
Terms of Guarantee
General sale and delivery terms of LAIRD apply. The buyer accepts these terms, at the latest when
signing the contract of purchase.
The particular terms of guarantee and duration of guarantee 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 product by
people that are not fully authorized
Use of the product despite of defect, wrongly implemented or non-functional safety units 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
NOTE
Any form of unintended use of the unit and any structural change caused by the user without
prior authorization in written form by
Laird Thermal Systems will lead to the termination of
warranty as well the termination
of the declaration of conformation and will free Laird Thermal
Systems from product liability. This concern includes 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 required safety devices.

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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 and year of manufacture
Company contact:
Laird Thermal Systems
Prumyslová 497
462 11 Liberec
Czech Republic

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2. Product Identification
Unit Specifications
Manufacturer
Laird Thermal Systems GmbH
Type of product
Water-air cooler
Type of unit
WL 3004
Article number
387002779
3. Unit specifications
Identification Plate
The identification plate is attached to the front side of the unit (see Fig. 1).
Fig. 1: Position of identification plate
1 Identification plate
Fig. 2: Unit specific identification plate
1 Unit type 2 Article number
3 Serial number 4 Electrical specifications
5
Date of manufacture
1
5
2
3
4
1

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2. Safety Regulations
Hazard classes
In this document safety instructions are using standardized representation and symbols. Depending
on the probability of their incidence and the severances of consequences three hazard classes are
used
CAUTION
Reference to noticeable danger for humans or possible damage to property.
Inobservance may lead to reversible injuries or to damage to property.
Safety Symbols
In this Operation Manual concrete safety instructions are given in order to point out unpreventable
residual risks when operating the unit. These risks include danger for
Human beings
The unit and other equipment
The environment
The safety symbols used in this 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
3. Warning signs
Symbol
Meaning
This symbol indicates that disconnecting from mains is required.
4. Signs giving orders
DANGER
Reference to direct danger for humans.
Inobservance will lead to irreversible injuries or exitus.

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Hints for Safe Operation
NOTE
Conduct inspections on a regular time base!
This will ensure that the appropriate measures will be carried out indeed.
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
is used improperly
is operated under unsuitable conditions
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 Operation 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 working with it
and within a regular time frame!
Make sure that nobody can injure himself by any part of the unit!
Any disruption or recognizable change concerning the unit should be reported to the responsible
person!
Stick to the accident prevention regulations as well as any regional regulations!
Hints Regarding the Electrical Equipment
When working on electrical installations the following principles should be observed:
Works on the electrical installations may only be accomplished by qualified electrical staff!
When connecting electrical equipment to mains regional regulations must be observed. Be aware
of the information in the wiring diagram!
The unit is powered by electricity. Electrical shock hazard exists, if the electrical installations are
defective or the insulation fails during operation.
When switched off the unit is not disconnected from mains. This is only the case when the mains
plug is pulled.
Any changes regarding the control elements of the unit can have an influence on the safe
operation. All intended changes must be authorized by the manufacturer.
After the implementation of a change the safeguard operations must be verified.
No unauthorized changes on the unit are allowed. All intended changes must be authorized by
the manufacturer.
DANGER
Danger to life through electrical shock when working on the electrical equipment of
the unit!
Switch off the unit before starting your work!
Disconnect the unit from mains by pulling the mains plug!
Verify that the installation is dead (volt-free)!

Carry out earthing or short circuiting!

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Environmental Issues
Environmentally conscious and anticipatory behavior of staff avoids environmentally hazardous
impacts.
The following principles apply for environmentally conscious behavior:
Environmentally hazardous substances must not get into the ground or the drains. They should
be kept in appropriate containers.
Environmentally hazardous substances must be fed to utilization or disposal according to
regional regulations.
When dealing with operating supplies always keep aware of the safety data sheet of the
corresponding manufacturer.
Safety Equipment
NOTE
The safety equipment listed below must be integrated in the local control environment by the customer,
unless otherwise noted. These works must be carried out only by trained experts.
All required
information can be taken from the wiring diagram shown in the addendum.
Safety equipment must not be modified, removed or taken out of operation. All parts of the safety
equipment must be accessible at all times.
Safety and Signaling Equipment included in the Unit
The unit is equipped with safety equipment at critical spots (see Fig. 2)
The water throughput is controlled by a flow control device that must be integrated in the
potential-free safety circuit of the device to be cooled.
The maximum temperature of the cooling circuit is controlled by a non-variable thermostat with
an opener contact that must be integrated into the safety circuit of the device to be cooled.
The maximum pump pressure is limited by a safety valve that by-passes the liquid stream when
the pressure pre-set is exceeded.
Fig. 3: Safety equipment
1
Safety valve
2
Thermostat
3 Flow control device

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Guards
Direct access to hazardous parts or areas of the unit is restricted by the unit cover. The cover may
only be removed for the purpose of maintenance or repair works and shall be replaced prior to taking
the unit back into operation. The unit cover is fixed by 8 screws. The left-side panel can be removed
independently from the main cover by opening 7 quarter-turn fasteners. The electrical terminal area is
accessible after removing the corresponding plate on the front side held by two screws. For
unscrewing/screwing or opening/closing of the fasteners a 7.0 x 1.0 mm slotted screwdriver is
required.
Fig. 4: Guards
1 Unit cover 2 Removable side panel
3
Access plate for electric terminal block
Caution Labels
Danger spots on the unit are indicated corresponding to German safety regulation BGV A8
"Sicherheits- und Gesundheitsschutzkennzeichnung am Arbeitsplatz".
Caution labels on the unit must be easily readable at all times. Illegible caution labels must be
exchanged without delay.
Fig. 5: Caution labels on the unit
1
Hint on electrical hazardous area behind access plate
2
1
3
1

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In Case of Accidents
Should you or another person be injured when working with the unit:
Stay calm!
Render first aid!
Call the company first-aider without exception!

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4. Product Description
Intended Use
The water-air cooler WL 3004 is used for the cooling of a water circuit. As a coolant water or a
water/glycol mixture may be used. The coolant circulates between the cooling unit and the device to
be cooled. It is re-cooled by an air-cooled heat exchanger. The maximum cooling capacity depends
on the difference between the ambient temperature and the temperature of the coolant forward flow.
Its value is 3000 Watts for a temperature difference of 12 K.
The unit is exclusively intended for use in industrial and commercial environments.
The intended use also includes the observance and following of all hints given in this Operation
Manual.
Use not in Conformance with the Intended Use
Operation of the unit under improper operational conditions is not allowed, since otherwise the
operation safety cannot be granted.
When using the unit in a way not compliant with the intended use, hazardous situations may occur.
Operation of the unit is not allowed under the following conditions:
The unit is used for a purpose other than the one it is intended for.
The unit or parts of it are damaged, the electrical installation is not correct or the insulation is
broken.
Protective or safety equipment is not functional or defect, improperly installed or missing.
The unit is not working properly.
Controlling devices were modified in a way that is not permitted.
Operational parameters were changed in a way that is not permitted.
Operation in areas exposed to explosion hazards
Operation with cooling media not according to specification
Use of unauthorized tools
Exceedance of the compulsory maintenance intervals
NOTE
The manufacturer is not liable for damage
occurring when using the unit in a way it was not intended for.
When using the unit in a
way it was not intended for, the manufacturer’s warranty given by Laird
Thermal Systems
will expire.

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Unit Components
Additional information can be retrieved from the flow scheme shown in the addendum. The unit
consists of the following main components:
Fig. 6: Main components
1
Coolant container and heat exchanger
2
Cooling circuit
3
Casing
Cooling Circuit
In the cooling circuit the coolant is driven by the pump to the device that is to be cooled and back via
the return flow. The heat is dissipated into the ambient air by an air-cooled heat exchanger.
Exceedance of the maximum pump pressure is prevented by a by-pass circuit.
The water temperature is controlled by an electric thermostat, whereas water throughput is controlled
by a flow control device. Both indications are made potential-free and must be integrated into the
safety circuit of the device to be cooled.
3

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Specifications
Dimensions and weight
Length:
444 mm (w/o hose nipples)
Width:
398 mm
Height:
481 mm
Weight:
38.5 kg (empty)
Coolant capacity:
3.7 liters
5. Dimensions and weight
Performance data
Cooling capacity:
3.0 kW
Throughput:
> 6.0 lpm at 6.0 bars
Mains voltage:
230 VAC, 50/60 Hz
Current draw:
2.5 A
6. Performance data
Environmental conditions
Operating temperature:
+5°C ... +40°C
Storage temperature:
-25°C ... +70°C (empty)
Relative humidity:
20% … 80%
7. Environmental conditions
Settings
Flow control device
4.0 ± 0.1 lpm (opening threshold)
Thermal switch
45°C ±5°C tolerance, 15°C hysteresis
Maximum pressure
8.0 ± 0.5 bars
8. Settings

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Setting-up Requirements
Installation Location
The location must be even.
When choosing the installation location, the following must be kept in mind: the air flow of the
cooling air must not be restricted, forward and back flow connections must be easily accessible
and all tubes must be installed without sharp bends.
Environmental Conditions
CAUTION
Risk of damage through unsuitable environmental conditions.
Damage to property and corrosion damage may result and are not covered by
manufacturer’s liability.
The unit is only authorized for use in indoor environments.
The unit must not be stored or operated in aggressive, humid environments.
The unit must not be stored or operated outdoor.
Pay attention to the environmental conditions as given in the specifications on page 16.
Infrastructure
The following infrastructure is required for connecting the unit:
Parameter
Rated value
Operating voltage
230 VAC
9. Required infrastructure

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5. Transport
Safety Indications for Transportation and Setting-up
CAUTION
Risk of injury by lifting the unit!
The weight of the unit is almost 40 kg.
Do not lift the unit manually!
Always use proper auxiliary means such as a forklift or a jack lift!
Transportation of the Unit
The unit is delivered wrapped in foil on a transportable pallet. Leave the unit on the pallet until
bringing it into service. Use a forklift or jack lift for transportation to the installation location.
Unpacking
Remove the foil before setting up the unit!
Inspect the unit regarding:
Damage caused by transportation
Completeness of delivery
Lift the unit with a forklift or jack lift off the transportable pallet.
Dispose of the packaging material in accordance with regional regulations.
NOTE
Laird Thermal Systems
advises to keep the transportable pallet for later transportation of the unit.

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6. Initial Operation
Safety Indications Related to Initial Operation
CAUTION
Danger of malfunction caused by faulty connections during initial operation!
Before switching on the unit make
sure that
all safety equipment of the unit is implemented and functional
all connections were properly made
Please follow the rules in chapter Safety Regulations on page 9.
Setting to Work
Placement
Fig. 7: Minimum clearance for air entrance and air exit
1
Ventilation grid
1) Move the unit to its installation location as mentioned in chapter 5.
2) Place the unit in a way that air entrance and air exit are not obstructed. Wall clearance must not be
less than 0.5 m, otherwise cooling capacity may be restricted.
NOTE
In case of storage of the
unit at temperatures lower than 5°C or higher than 40°C for longer periods
please wait 3 hours prior to initial operation to allow for temperature adjustment.
1
1
0.5 m min.
0.5 m min.

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Cooling Circuit Connection and Filling
CAUTION
Risk of damage by using improper cooling hoses!
This may lead to damage to persons, damage to the unit or
corrosion damage.
When choosing cooling hoses pay attention to sufficient burst strength and compatibility with
coolant!
Only use cooling hoses without any signs of damage!
The cooling hoses with an internal diameter of 9 mm are connected to the unit by means of hose
nipples. Water outlet and water inlet are indicated with respective symbols.
Fig. 8: Labeling of water inlet and water outlet
1) Connect a suitable hose to the hose nipples for water inlet and water outlet and secure it with a
clamp respectively.
2) Connect the hoses to the corresponding nipples of the device to be cooled.
NOTE
When connecting the cooling hoses pay attention to flow direction. Follow the documentation released
by the manufacturer of the device to be cooled.
Transparent hoses stimulate algae growth that may increase the error
-proneness of the components
built into the unit.
Thus, only use non-transparent hoses.
Fig. 9: Cap of coolant container
1
Cap
Water inlet
Water outlet
1