Laird WW 5001 User manual

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Operation Manual
Water-Water Cooler WW 5001
Version 1.0

Laird Technologies GmbH
Borsigstrasse 1
D-24568 Kaltenkirchen
www.lairdtech.com
Protection Notice
Dissemination as well as copying of this document, utilization or posting of its contents is not permitted
unless formally granted. Violations entail claims for compensation. All copyrights, including rights due to
patent grant or registration of a utility model or design, are reserved.
All product names used in this manual are trademarks of the corresponding manufacturers.
Technical modifications are subject to change.

Table of Contents
3
Laird Technologies GmbH
Operation Manual
Date: 28-October-2015
Version: 1.0
Water-Water Cooler WW 5001
1109.00
Table of Contents
1About this Manual ............................................................................................................................ 6
1.1 Terms of Guarantee.............................................................................................................................6
1.2 Contact Information..............................................................................................................................7
2Product Identification....................................................................................................................... 8
2.1 Unit Specifications................................................................................................................................8
2.2 Identification Plate ................................................................................................................................8
3Safety Regulations........................................................................................................................... 9
3.1 Hazard classes......................................................................................................................................9
3.2 Safety Symbols.....................................................................................................................................9
3.3 Hints for Safe Operation .................................................................................................................. 10
3.3.1 Prevent Hazards ..................................................................................................................................................... 10
3.3.2 Hints Regarding the Electrical Equipment.............................................................................................................. 11
3.3.3 Environmental Issues.............................................................................................................................................. 11
3.3.4 Exclusion Criteria .................................................................................................................................................... 11
3.4 Safety Equipment.............................................................................................................................. 12
3.4.1 Safety and Signalling Equipment included in the Unit............................................................................................ 12
3.4.2 Guards..................................................................................................................................................................... 13
3.4.3 Caution Labels ........................................................................................................................................................ 13
3.5 In Case of Accidents......................................................................................................................... 14
4Product Description ....................................................................................................................... 15
4.1 Intended Use ...................................................................................................................................... 15
4.2 Non-Conformity with the Intended Use........................................................................................ 15
4.3 Unit Components............................................................................................................................... 16
4.3.1 Functional principle ................................................................................................................................................. 16
4.4 Specifications...................................................................................................................................... 17
4.5 Setting-up Requirements................................................................................................................. 18
4.5.1 Installation Location................................................................................................................................................. 18
4.5.2 Environmental Conditions....................................................................................................................................... 18
4.5.3 Infrastructure ........................................................................................................................................................... 18
5Transport.......................................................................................................................................... 19

Table of Contents
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Laird Technologies GmbH
Operation Manual
Date: 28-October-2015
Version: 1.0
Water-Water Cooler WW 5001
1109.00
5.1 Safety Indications for Transportation and Setting-up ............................................................... 19
5.2 Transportation of the Unit ................................................................................................................ 19
5.3 Unpacking and Disposal of Packaging Material........................................................................ 19
6Initial Operation............................................................................................................................... 20
6.1 Safety Indications Related to Initial Operation ........................................................................... 20
6.2 Setting to Work................................................................................................................................... 20
6.2.1 Placement ............................................................................................................................................................... 20
6.2.2 Cooling Circuit Connection and Filling.................................................................................................................... 21
6.2.3 Electrical Connections ............................................................................................................................................ 22
6.2.4 Carrying out Setting to Work................................................................................................................................... 23
6.3 Daily Start-up ...................................................................................................................................... 23
6.4 Setting to work after Storage .......................................................................................................... 23
7Controlling the Unit ........................................................................................................................ 24
7.1 Safety Indications for Controlling the Unit ................................................................................... 24
7.2 Switching-on the Unit........................................................................................................................ 24
7.3 Switching-off the Unit........................................................................................................................ 24
7.4Settings................................................................................................................................................. 25
7.4.1 Flow Control Device................................................................................................................................................ 25
7.4.2 By-pass Valve ......................................................................................................................................................... 25
7.4.3 Temperature Controller........................................................................................................................................... 25
8Disruptions....................................................................................................................................... 28
8.1 Safety Instructions in the Event of Malfunction.......................................................................... 28
8.2 Disruption in Operation..................................................................................................................... 28
8.2.1 Trouble Shooting..................................................................................................................................................... 29
9Maintenance and Cleaning ......................................................................................................... 30
9.1Maintenance Schedule..................................................................................................................... 30
9.2 Refilling of Coolant............................................................................................................................. 30
9.3 Cleaning of Strainer........................................................................................................................... 31
9.4 Cleaning of Unit Body....................................................................................................................... 32
10 Repair ............................................................................................................................................... 32
10.1 Safety Instuctions on Repair........................................................................................................... 32
10.2 Repair Procedures............................................................................................................................. 32

Table of Contents
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Laird Technologies GmbH
Operation Manual
Date: 28-October-2015
Version: 1.0
Water-Water Cooler WW 5001
1109.00
11 Dismounting, Disposal, Storage................................................................................................. 33
11.1 Temporary Placing out of Operation ............................................................................................ 33
11.2 Re-packaging of the unit.................................................................................................................. 34
11.3 Storing the Unit................................................................................................................................... 34
11.4 Disposal ............................................................................................................................................... 34
11.5 Disposal of Operating Materials..................................................................................................... 34
11.6 Return of the unit to LAIRD............................................................................................................. 34
12 Wear Parts and Spare Parts....................................................................................................... 35
12.1 General Information.......................................................................................................................... 35
12.2 Parts Overview................................................................................................................................... 36
Addendum ............................................................................................................................................. 37
Flow scheme................................................................................................................................................. 37
Wiring diagram.............................................................................................................................................. 38
History of Changes
Date
Index
Reason for Change
Name
Page
28-October-2015
1.0
Dany/Bitenaite

About this Manual
Terms of Guarantee
6
Laird Technologies GmbH
Operation Manual
Date: 28-October-2015
Version: 1.0
Water-Water Cooler WW 5001
1109.00
1 About this Manual
This document is the English translation of the original Operation Manual in German language for the Water-
Water Cooler WW 5001 (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.
1.1 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 device 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 devices or
protective gear
Unauthorized or forbidden modifications by the user concerning the electrical equipment of the unit
Unauthorized or forbidden modifications by the user concerning the mechanical structure of the unit
Unauthorized or forbidden modifications by the user concerning the operating parameters
Use of unauthorized tools
Use of unauthorized operating supplies
Exceedance of mandatory maintenance intervals
Cases of disaster caused by foreign matter influence or act of nature beyond control
PLEASE 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 will lead to the termination of warranty as well the termination of the
declaration of conformation and will free LAIRD 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.

About this Manual
Contact Information
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Laird Technologies GmbH
Operation Manual
Date: 28-October-2015
Version: 1.0
Water-Water Cooler WW 5001
1109.00
1.2 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:
Mail:
Laird Technologies GmbH
Borsigstrasse 1
D-24568 Kaltenkirchen
Deutschland
Internet:
http://www.lairdtech.com
E-Mail:
[email protected]
Phone:
[phone]
Fax:
[phone]

Product Identification
Unit Specifications
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Laird Technologies GmbH
Operation Manual
Date: 28-October-2015
Version: 1.0
Water-Water Cooler WW 5001
1109.00
2 Product Identification
2.1 Unit Specifications
Manufacturer
Laird Technologies GmbH
Type of product
Water-water cooler
Type of unit
WW 5001
Article number
1109.00
Table 1: Unit specifications
2.2 Identification Plate
The identification plate is attached to the front side of the unit (see picture 1).
Fig. 1: Position of identification plate
1
Identification plate
Fig. 2: Unit specific identification plate
1
Unit type
2
Date of manufacture
3
Article number
4
Serial number
5
Electrical specification
1
2
3
4
5
1

Safety Regulations
Hazard classes
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Laird Technologies GmbH
Operation Manual
Date: 28-October-2015
Version: 1.0
Water-Water Cooler WW 5001
1109.00
3 Safety Regulations
3.1 Hazard classes
In this document safety instructions are using standardized representation and symbols. Depending on the
probability of their incidence and the severeness of consequences three hazard classes are used.
DANGER
Reference to direct danger for humans.
Inobservance will lead to irreversible injuries or exitus.
CAUTION
Reference to noticeable danger for humans or possible damage to property.
Inobservance may lead to reversible injuries or to damage to property.
3.2 Safety Symbols
In this Operation Manual concrete safety instructions are given in order to point out unpreventable residual
risks when operating the device. These risks include danger for
Human beeings
The device 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
Table 2: Warning signs

Safety Regulations
Hints for Safe Operation
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Laird Technologies GmbH
Operation Manual
Date: 28-October-2015
Version: 1.0
Water-Water Cooler WW 5001
1109.00
Symbol
Meaning
This symbol indicates the requirement of disconnecting from mains
Table 3: Signs giving orders
3.3 Hints for Safe Operation
PLEASE NOTE
Conduct inspections on a regular time base.
This will ensure that the appropriate measures will actually be carried out.
The unit is operational safe. It was built according to the state-of-the-art.
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
3.3.1 Prevent Hazards
Hazards can be prevented by safety-conscious and anticipatory behaviour 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 state!
Use the unit exclusively for what it was intended!
The unit must be operational and errorfree. 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!

Safety Regulations
Hints for Safe Operation
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Laird Technologies GmbH
Operation Manual
Date: 28-October-2015
Version: 1.0
Water-Water Cooler WW 5001
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3.3.2 Hints Regarding the Electrical Equipment
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!
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 have to be observed. Be
aware of the wiring diagram information.
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 implementation of any change the operativeness of the safeguards must be verified.
No unauthorized changes on the unit are allowed. All intended changes must be authorized
by the manufacturer.
3.3.3 Environmental Issues
Environmentally conscious and anticipatory behaviour of staff avoids environmentally hazardous impacts.
The following principles apply for environmentally conscious behaviour:
Environmentally hazardous substances must not get into the ground or in 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.
3.3.4 Exclusion Criteria
PLEASE NOTE
Operating Staff
Staff is only allowed to operate the unit. They are neither allowed to open the unit chassis, remove parts,
connect or disconnect power or coolant fluids nor to do maintenance.

Safety Regulations
Safety Equipment
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Laird Technologies GmbH
Operation Manual
Date: 28-October-2015
Version: 1.0
Water-Water Cooler WW 5001
1109.00
3.4 Safety Equipment
PLEASE 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 solely 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.
Familiarize yourself with all safety equipment. This can prevent or minimize bodily harm and/or unit failure in
case of disaster.
3.4.1 Safety and Signalling Equipment included in the Unit
The unit is equipped with safety devices at critical spots (see Fig. 2).
Water throughput is controlled by a flow switch 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 fixed 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.
The level of the cooling fluid container can be monitored against the state “empty”
Fig. 3: Safety devices
1
Safety valve
2
Thermostat
3
Flow switch
4
Cooling container level sensor
1
3
2
4

Safety Regulations
Safety Equipment
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Laird Technologies GmbH
Operation Manual
Date: 28-October-2015
Version: 1.0
Water-Water Cooler WW 5001
1109.00
3.4.2 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 four M5 screws.
The electrical terminal area is accessable after removing the back cover. For opening/closing of the
fasteners an AF8 wrench is required.
Fig. 4: Guards
1
Unit body
2
Access bushing for electric terminal block
3
Removable back cover
3.4.3 Caution Labels
Danger spots on the unit are indicated in correspondence 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
immediately.
Fig. 5: Caution labels on the unit
1
2
3
1

Safety Regulations
In Case of Accidents
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Laird Technologies GmbH
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Version: 1.0
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1
Hint on electrical hazardous area at the back of the unit body
3.5 In Case of Accidents
Should you or an other person be injured when working with the unit:
Stay calm
Render first aid
Call the company first-aider without exception

Product Description
Intended Use
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Laird Technologies GmbH
Operation Manual
Date: 28-October-2015
Version: 1.0
Water-Water Cooler WW 5001
1109.00
4 Product Description
4.1 Intended Use
The water-water cooler WW 5001 is used for the cooling of a water circuit. As a coolant pure water or a
water/antifreeze mixture may be used. The coolant circulates between the cooling unit and the device to be
cooled. The cooling capacity depends on the temperature and flowrate of the cooling water (tap water). Its
value is 3000 Watts at 5.0 l/min cooling water with 22°C.
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.
4.2 Non-Conformity with the Intended Use
Operation of the unit under improper operational conditions is not allowed, as otherwise the safe operation
can not be assured.
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.
The unit has been mofified in any way.
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 compulsary maintenance intervals
PLEASE NOTE
The manufacturer is not liable for damage occuring 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 will
expire.

Product Description
Unit Components
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Laird Technologies GmbH
Operation Manual
Date: 28-October-2015
Version: 1.0
Water-Water Cooler WW 5001
1109.00
4.3 Unit Components
The unit consists of the following sub-assemblies .Additional information can be retrieved from the flow
scheme shown in the addendum.
Fig. 6: Main components
1
Coolant container and plate heat exchanger
2
Cooling circuit
3
Body
4.3.1 Functional principle
In the cooling circuit the coolant (water or wator/glycol) is driven by the pump to the device that is to be
cooled and back via the return flow. The heat is transferred to the cooling water through a plate heat
exchanger following the principle of opposing flows. The heat is then dumped from the unit by the cooling
water.
The coolant temperature is controlled by an electric thermostat, whereas coolant 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.
2
3
1

Product Description
Specifications
17
Laird Technologies GmbH
Operation Manual
Date: 28-October-2015
Version: 1.0
Water-Water Cooler WW 5001
1109.00
4.4 Specifications
Dimensions and weight
Length:
450 mm
Width:
300 mm
Height:
370 mm
Weight:
24.0 kg (empty)
Coolant contents:
8.5 Liters
Table 4: Dimmensions and weight
Performance data
Cooling capacity:
5000 W
Throughput:
> 10 lpm at 4.0 bars
Mains voltage:
230 VAC, 50/60 Hz
Current draw:
1.0 A
Operating noise:
≤48 dB (50 Hz) @ 1 m distance
Table 5: Performance data
Environmental conditions
Operating temperature:
+0°C ... +40°C
Storage temperature:
-20°C ... +70°C (empty)
Relative humidity:
10% … 90%
Table 6: Environmental conditions
Settings
Maximum pressure
6.5 bars ± 0.2 bars
Flow switch off
4.0 lpm
Water supply temperature
25°C
Maximum temperature
35°C ± 3°C
Table 7: Settings

Product Description
Setting-up Requirements
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Laird Technologies GmbH
Operation Manual
Date: 28-October-2015
Version: 1.0
Water-Water Cooler WW 5001
1109.00
4.5 Setting-up Requirements
4.5.1 Installation Location
The location must be even.
When choosing the installation location the following must be kept in mind:
othe air flow of the cooling air for the motor must not be restricted
oforward and back flow connections must be easily accessable
oall tubes must be installed without sharp bends
4.5.2 Environmental Conditions
CAUTION
Risk of damage due to unsuitable environmental conditions!
Damage to the unit 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 agressive, humid environments.
The unit must not be stored or operated outdoor.
Pay attention to the environmental conditions as given in the specifications on page 17.
4.5.3 Infrastructure
The following infrastructure is required for connecting the unit:
Parameter
Rated value
Operating voltage
230 VAC, 50/60Hz
Table 8: Required infrastructure

Transport
Safety Indications for Transportation and Setting-up
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Laird Technologies GmbH
Operation Manual
Date: 28-October-2015
Version: 1.0
Water-Water Cooler WW 5001
1109.00
5 Transport
5.1 Safety Indications for Transportation and Setting-up
CAUTION
Risk of injury by lifting the unit!
The weight of the unit is almost 24 kg (empty).
Do not lift the unit manually!
Always use proper auxiliary means such as a forklift or a jack lift!
CAUTION
Risk of damage by improper transportation!
The attachments of different components inside the unit are not secured with transportation locks. In case
of improper transportation these can be damaged without repair and would need to be replaced.
Transport the unit in upright position!
Do not tilt the unit or expose it to impacts!
5.2 Transportation of the Unit
The unit is delivered packaged and shrinked 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.
5.3 Unpacking and Disposal of Packaging Material
Remove the foil before setting up the unit. Inspect the unit with regard to:
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.
PLEASE NOTE
LAIRD advises to keep the transportable pallet and packaging material for later transportation of the unit.