Lauda Ultracool Superplus series User manual

OPERATION MANUAL
ultracool mini
0140 Indigo
Ref:MI-080 Rev: 1Date: 30.04.03
50/60 Hz

- -
1
Warnings
Warnings
This Operation Manual is to be followed by all persons
working with the unit. It is imperative that this Manual is made
freely available at all times to service personnel and is kept at
the point where the unit is installed.
The basic maintenance, as indicated in point 5.1, should be
carried out by properly trained personnel and, if necessary,
under the supervision of a person qualified for this job.
ultrafilter personnel, or personnel authorised by ultrafilter,
should carry out any work in the refrigerating or electric
circuit during the warranty period. After the warranty period,
the work must be carried out by qualified personnel.
UC-140 INDIGO 50/60Hz 29.01.03 rev. 0

- -
2
Table of Contents
Table of Contents
1 Introduction
1.1 General notes 3
1.2 Safety regulations 3
2 Installation
2.1 Reception and inspection 4
2.2 Transportation 4
2.3 Site 4
2.4 Installation 5
2.5 Identification labels on the ultracool unit 5
2.6 Water connection 6
2.7 Electric connection 6
3 Start-up
3.1 Operating conditions 7
3.2 Before the start-up of the ultracool unit 7
3.3 Chiller strat-up 8
4 Control Panel
4.1 Components of the control panel 9
4.2 Control thermostat 10
4.2.1 Operation 10
5 Maintenance
5.1 Basic maintenance 11
6 Troubleshooting
6.1 Possible causes of defaults 12
7 Technical Features
7.1 Technical Features 14
8 Log Book
8.1 Log Book 15
9 Annexes
9.1 Water Quality 16
10 Spare Parts
10.1 Spare parts 17
11 Technical Diagrams
11.1 Dimensional sheet
11.2 Flow sheet
11.3 Wiring sheet
Attention. Points of special interest to keep in mind.
UC-140 INDIGO 50/60Hz 29.01.03 rev. 0

- -
3
1 Introduction
1 Introduction
1.1 General notes
•This water chiller complies fully with EC-machine directives and is UL and
CSA listed.
•The Company does not accept responsibility if safety regulations are not met
during handling, operation, maintenance and repair, even though these may
not be strictly stated in this operation manual.
•We recommend the translation of this operation manual into the native
language of foreign workers.
•The usability and life cycle of the water chiller as well as avoiding premature
repairs depends on proper operation, maintenance, care and competent repair
under consideration of this operation manual.
•We are constantly updating our products and are confident that they respond
to the latest scientific and technological demands. However, as
manufacturers, we do not always know the end use or the total range of our
products’ applications. Therefore we cannot accept liability for our products in
applications where additional safety measures may be necessary. We highly
recommend that users inform us of the intended application in order to
undertake additional safety measures, if necessary.
1.2 Safety regulations
The operator has to observe the national working, operating and safety
regulations. Also, existing internal factory regulations must be met.
Maintenance and repair work must only be carried out by specially trained
personnel and, if necessary, under supervision of a person qualified for this
work.
•Protective or safety devices must not be removed, modified or readjusted.
•During operation of the water chiller none of the protective or safety devices
must be removed, modified or readjusted, temporarily or permanently.
•Only use correct tools for maintenance and repair work.
•Use original spare parts only.
•All maintenance and repair work must only be carried out to the machine
once it has been stopped and disconnected from the power supply. Ensure
that the water chiller cannot be switched on by mistake by unplugging it.
•Do not use flammable solvents for cleaning.
•Keep the surrounding area absolutely clean during maintenance and repair
work. Keep free of dirt by covering the parts and free openings with clean
cloth, paper or adhesive tape.
•Ensure that no tools, loose parts or similar are left inside the system.
UC-140 INDIGO 50/60Hz 29.01.03 rev. 0

- -
4
2 Installation
2 Installation
2.1 Reception and Inspection
On receipt of the ultracool unit, it must be inspected for damage during
transport. In the case of any damage, external or internal, this cannot be
referred to the manufacturer because all units are checked before
dispatch. If any damage is observed, this should be documented
and reported to the forwarding company. The ultrafilter warranty
does not include any damages incurred during transportation.
The refrigerant circuit controls are set before shipment of the unit. They
should not be re-adjusted under any circumstances (except by our
ultrafilter service department). This would void the warranty of the unit.
2.2 Transportation
Keep the unit upright at all times. Do not tilt when shipping or moving.
The tilting of the ultracool unit may affect the internal suspension
of the refrigerant compressor.
The ultracool unit must be transported by palet jack or forklift truck.
2.3 Site
The ultracool unit must be installed in an atmosphere where the range of
temperatures is within the indicated margins mentioned in point 3.1. For
ambient temperatures lower than 5ºC (41ºF) it is necessary to add
ethylene glycol to the water of the circuit, as indicated in point 2.4.
We recommend the installation of the ultracool unit in a well-ventilated
site and in a corrosive-free, dust-free atmosphere.
In the case of out-door installation the chiller must be protected from rain
with a roof and it must be installed in such way that the control panel
receives as few direct sunlight as possible.
A space of 1 m (4 ft) should be left around the ultracool unit to facilitate
maintenance work and cleaning, especially in front of the condensor
grid. The inlet of fresh air onto the condensor should be in the most
direct way possible, avoiding any chance of air recycling (the ceiling
above should not be at less than 1 m (4 ft)).
UC-140 INDIGO 50/60Hz 29.01.03 rev. 0

- -
5
2 Installation
2.4 Installation
The ultracool units must always operate with the panels closed to
enable the inlet of fresh air only through the condensor.
If the operation of the ultracool unit is with ambient temperatures below
5ºC (41ºF), ethylene glycol must be added to the water of the
installation. The ethylene glycol concentration is obtained according to
the following chart.
Ambient temperature ºC (ºF) 5(41) -5(23) -15(5)
% Ethylene glycol 10 20 30
The ethylene glycol percentage is given as % measured as weight of the
total mixture.
In the case of any modification in the quantity of water in the installation,
the concentration of ethylene glycol should be checked.
Do not use automotive antifreeze. Use lab grade ethylene glycol or
refrifluid only! Do not use an ethylene glycol concentration above
the 30%; this would damage the water pump.
2.5 Identification Labels on the ultracool unit
You can find the following labels stuck on the ultracool unit.
Water inlet from the
installation to the
ultracool unit.
Water outlet from
the ultracool unit to
the installation.
Connection to fill the
tank.
Drain. Connection for the tank
overflow.
Arrow showing
turn direction of
pump.
Three phase
supply at 400V
and 50 Hz.
Danger of cuts! Completely
disconnect the chiller’s power
supply before opening this cover.
Three phase
supply at 230V
and 60 Hz
230V/3Ph/60Hz 400V/3Ph/50Hz
UC-140 INDIGO 50/60Hz 29.01.03 rev. 0

- -
6
2 Installation
2.6 Water Connection
It is necessary to install a water filter at the inlet of the chiller in order to
avoid free particles in the water, which could block the evaporator plates
or damage the pump. ultrafilter will not accept any warranty for the
evaporator freezing if there is no water filter. An appropriate filter is the
ultrafilter P-KG with a PPTF or similar with a filter element of 100
microns or less.
The water connection of the installation of the ultracool unit should be
carried out according to the indications of the labels (stickers) present on
the unit.
The diameter of the inlet and outlet lines must be same size or larger
than those corresponding to the water inlet and outlet of the ultracool
unit. Always install thermal insulation for all pipes.
In the installations in which the water level of the circuit exceeds
the maximum level of the tank inside the ultracool unit, it will be
necessary to install a non-return valve in the water outlet of the
ultracool unit and a solenoid valve in the water inlet.
The supply of this solenoid valve will be carried out by terminals
designed for that purpose (see electrical diagrams).
2.7 Electrical Connection
The electrical design of the ultracool complies with UL 471 and
EN-60204 norms.
The electrical supply is 400V/3~/50Hz or 230V/3~/60Hz depending on
the version.
It must be checked that the supply voltage does not exceed a maximum
variation of 10% referring to nominal.
For the electrical supply of the ultracool unit, use an appropriate
electrical line according to the data in the characteristics plate.
A system of fuses or circuit breakers must be installed before the
power inlet connection to the ultracool unit. The maximum size of
these protections is defined in the electrical diagram.
There are two prepared terminals to connect a remote on-off switch
away from the unit. These terminals are at 24V.
There are two prepared terminals in order to connect a solenoid valve to
the water inlet to the ultracool unit, in such a way that when the ultracool
unit starts, the solenoid valve opens up. These terminals are at 24VAC.
UC-140 INDIGO 50/60Hz 29.01.03 rev. 0

- -
7
3 Start-up
3 Start-up
3.1 Operation Conditions
The control thermostat in the chiller will control it in order to maintain the
preset cold water temperature.
Water temperature at the inlet:
Nominal: 15ºC (60ºF)
Maximum: 30ºC (86ºF)
Cold water temperature at the outlet:
Nominal: 10ºC (50ºF)
Minimum: 5ºC (40ºF) (1)
Maximum: 15ºC (60ºF)
(1) To reach this temperature it is necessary to add a 10% ethylene
glycol to the water and contact an authorised technical service to adjust
the chiller.
Temperature of the ambient air:
Nominal: 25ºC (77ºF)
Minimum: -15ºC (5ºF) (2)
Maximum: 50ºC (122ºF)
(1) For ambient temperatures below 5ºC (40ºF) it is necessary to add
ethylene glycol to the water of the circuit (see point 2.4).
3.2 Before start-up of the ultracool unit
Clean the application water circuit with tap water in order to be sure that
there are no free particles. Otherwise the filter elements can block up
during the start up process.
The following points must be checked:
- Lateral panels closed.
- Filling of the water circuit of the ultracool unit (see point 4.3).
- Water connections.
- Connection valves to the water line are open.
- External circuit protection is connected.
UC-140 INDIGO 50/60Hz 29.01.03 rev. 0

- -
8
3 Start-Up
3.3 Chiller start-up
When the ultracool unit is started for the first time, it is necessary to turn
ON the Main power switch (element 1 in the control panel, see point 4)
and wait six hoursbefore continuing with the start-up sequence. This
time is necessary for the crankcase of the compressor to heat it up.
The oil in the crankcase of the compressor remains warm whenever the
main power switch is in the ON position and the unit is connected to the
line voltage. For this reason stop the ultracool unit by using the off-
switch, leaving the Main power switch in the ON position.
Fill the tank with water of the required quality (see annex 9) or with
refrifluid through the provided connection until the maximum level of the
tank is reached.
Start the ultracool unit with the On/Off switch (element 2 in the control
panel, see point 4). Stop the ultracool unit and refill the tank to the
correct water level.
Repeat this procedure until the water level in the tank remains constant.
It’s necessary to verify the direction of rotation of the pump at the
initial start up. To do so, start and stop the ultracool unit, using the
On/Off switch (it is easier to see the turn direction when the pump is
stopping). In the case of the pump rotating in the opposite direction from
the indicated, it will be necessary to exchange two phases in the main
power supply. It will not be necessary to check the turn direction of the
fans, because they are delivered in phase with the pump. Since it may
be difficult to see the pump’s rotation direction, verify that you did this
operation correctly when the motor fan starts working: The air should
enter the condenser and go out through the top of the chiller. If the air is
moving in the opposite direction then exchange two phases in the main
power supply.
Connect the On/Off switch so that the ultracool unit starts. At the same
time the digital thermometer and all the indicators that should light up will
turn on too, according to their function.
On the control thermostat select the desired temperature of the cold
water outlet (see point 4.2.1). The ultracool units are delivered with a
pre-set temperature of 10ºC (50ºF).
Adjust the water pressure, using an external valve at the ultracool outlet,
to the value indicated on the data plate (Nominal pressure).
UC-140 INDIGO 50/60Hz 30.04.03 rev.1

- -
9
4 Control Panel
4 Control Panel
4.1 Components of the Control Panel
The control panel consists of the following elements:
1. Main power switch: connects and disconnects the ultracool unit
from the power supply.
2. On-Off switch: starts up the different elements that make up the
ultracool unit.
3. Water gauge: indicates the working pressure of the pump.
4. Control thermostat: indicates the cold water temperature at the
outlet of the ultracool unit and enables it to be regulated.
5. Pump indicator: this remains lit when the pump is working.
6. Compressor indicator: this remains lit when the compressor is
working.
7. Water level alarm indicator: this is lit when the water level in the
tank is too low. It causes the ultracool unit to stop.
8. Low flow/temperature control indicator: This flow control can stop
the compressor when there is no water circulation through the
external water circuit. In this case some flow still circulates inside the
chiller. The temperature control can also stop the compressor when
you try to reach water temperatures below 7ºC (45ºF). To be able to
reach temperatures below that contact an authorised technical
service.
9. Low refrigerant pressure alarm indicator: this is lit when the
pressure of the refrigerating circuit is below the minimum allowed. It
causes the refrigerant compressor to stop.
UC-140 INDIGO 50/60Hz 29.01.03 rev. 0

- -
10
4 Control Panel
10. High refrigerant pressure alarm indicator: this is lit when the
pressure of the refrigerating circuit is higher than the maximum
allowed. It causes the refrigerant compressor to stop.
4.2 Control Thermostat
Display in ºC Display in ºF
4.2.1 Operation
During normal operating conditions, the display of the control
thermostat shows the cold water temperature measured by the
probe. In the 50Hz version the display shows the temperature in ºC
and in the 60Hz version it shows it in ºF as depicted above.
Setting the temperature: Follow these steps to introduce the required
working temperature:
- Hold down for 2 seconds the button SEL and the current set
temperature will start flashing.
- To increase or to decrease the value of the setpoint, use the UP and
DOWN buttons.
- Press SEL again to confirm the new value.
If an alarm sounds: press the button PRG to silence the alarm. The
alarm code will stay until the cause of the alarm disappears.
UC-140 INDIGO 50/60Hz 29.01.03 rev. 0

- -
11
5 Maintenance
5 Maintenance
5.1 Basic Maintenance
Weekly:
Verify that the water temperature indicated on the control thermostat is
approximately at the setpoint.
Verify the pressure of the pump.
Verify the water level in the tank.
Verify the state of the water filter, if the pressure drop exceeds 0.5 bar (8
psi) change the filter element.
Monthly:
With the Unit disconnected (Main power switch Off), clean the
condenser with a blast of compressed air, from the inside towards the
outside.
Clean the housing, internally and externally, eliminating the dust present
especially on the water pump rack.
Yearly:
Change the filter element and refill the water circuit with clean water or
refrifluid.
UC-140 INDIGO 50/60Hz 29.01.03 rev. 0

- -
12
6 Troubleshooting
6 Troubleshooting
In the following chart the possible causes for an alarm are given together with their
solution:
DEFAULT CAUSE SOLUTION RESTART PROCEDURE
Alarm due to high
pressure of the
refrigerant
Lateral panels of
the housing open
Low airflow into
the condensor
The ambient
temperature is too
high
Water temperature
too high
Motor fan not
working
Close the panels
Clean the condensor
Wait until the ambient
temperature is lower
Try to cool down the
water in the circuit
running the chiller with
the application stopped
Check the motor fan
fuses. If the problem
persists contact
authorised technical
service.
Disconnect the chiller
(On/Off and Main power
switch both Off, see point
4). Open the front panel of
the chiller and reset the
High-pressure safety
switch (SHP) by pressing
its button. Turn both the
Main power switch and the
On/Off switch back on.
Alarm due to low
pressure of the
refrigerant
Gas leakage Contact authorised
technical service.
The Low-pressure safety
switch (SLP) automatically
resets itself when the
pressure is back to normal
Water level alarm Water leakage Check the water circuit
and refill the tank.
The level switch
automatically resets itself
when there is enough
water in the tank
UC-140 INDIGO 50/60Hz 29.01.03 rev. 0

- -
13
6 Troubleshooting
DEFAULT CAUSE SOLUTION RESTART PROCEDURE
Low flow/temperature
control operates
continuously (see point
4)
Water circuit
blocked
Possible freezing
Circuit break in the
pump
Clean the water circuit,
check for closed valves
in the circuit.
Check the proportion of
ethylene glycol.
Reset the circuit
breaker of the pump. If
the problem persists
contact authorised
technical service
The control will go back to
normal operation when the
problem is solved
The control thermostat
displays the following
codes:
LO
HI
E0, Er2, EE
The temperature
has been below
the setpoint for
some minutes
The temperature
has been above
the setpoint for
some minutes
Thermostat or
temperature
sensor is faulty
If the compressor is
stopped the water
temperature will rise to
normal eventually. If
the compressor is still
running contact
authorised technical
service
Check that the cold
water setpoint is within
the limits indicated on
point 3.1. If the
problem persists
contact authorised
technical service
Contact authorised
technical service
The chiller is still working
normally
The chiller is still working
normally
The chiller can be restarted
when the faulty part is
replaced
UC-140 INDIGO 50/60Hz 29.01.03 rev. 0

- -
14
7 Technical Features
7 Technical Features
UC 140 Indigo 50Hz 140 Indigo 60Hz
Cooling capacity kW (ton) 15.3 (4.3) 17.4 (4.9)
Water flow l/h (US gal/min) 2628 (11.6) 2566 (11.3)
Water pressure bar (psi) 5.1 (74) 4.8 (70)
Refrigerant charge kg (lb) R134a 14 (31) 14 (31)
Compressor kW 4.0 5.3
Condenser kW (ton) 24.0 (6.8) 24.0 (6.8)
Evaporator kW (ton) 19.4 (5.5) 19.4 (5.5)
kW 0.7 1.0
Motor fan m3/h (scfm) 8300 (4885) 8300 (4885)
kW 1.1 1.0
max flow 4000 (17.6) 4000 (17.6)
min flow l/h (US gal/min) 400 (1.8) 400 (1.8)
max pres. 6.3 (91) 6.3 (91)
Water pump
min pres. bar (psi) 3.3 (48) 3.3 (48)
Water tank volume litre (US gal) 100 (26) 100 (26)
Water connections 1" BSP 1" NPT
Front mm (in) 845 (33) 845 (33)
Depth mm (in) 990 (39) 990 (39)
Dimensions
Height mm (in) 1235 (49) 1235 (49)
Weight kg (lb) 260 (573) 260 (573)
Power kW 5.8 7.3
Max. Current A 16 30
Voltage V/P/Hz 400/3/50 Hz 230/3/60 Hz
Nominal COP 3.26 2.76
All data related to the following conditions: Water outlet temperature 10ºC (50ºF) and ambient
temperature 25ºC (77ºF).
UC-140 INDIGO 50/60Hz 29.01.03 rev. 0

- -
15
8 Log Book
8 Log Book
8.1 Log Book
Date Remarks Signature
UC-140 INDIGO 50/60Hz 29.01.03 rev. 0

- -
16
9 Annexes
9 Annexes
9.1 Water quality
In order to protect the water circuit of the ultracool units, the water to be
cooled must have specific physical/chemical properties so that it is not
aggressive. If this water is outside any of the limits listed in the table
below, it can seriously damage some of the materials of the ultracool
unit.
Parameter Limit values
pH 7 – 8
Total Hardness (TH) < 150 ppm
Conductivity 50 – 500 µS/cm
NH3< 2 ppm
Total iron ions (Fe2+ and Fe3+) < 0.2 ppm
Chloride (Cl-) < 300 ppm
H2S < 0.05 ppm
Solid particles < 150 µm
The Total Hardness is specified in ppm (mg/L) of Ca2CO3.
Please note that ultra pure waters like deionised water can also be
harmful for some of the materials of the ultracool units as they have a
conductivity below 50 µS/cm.
The product refrifluid supplied by ultrafilter includes in its composition an
anticorrosive, bactericide and antifreeze (until –7ºC / 19.4 ºF). It has the
following characteristics:
Parameter Limit values
pH 7.5
Total Hardness (TH) < 30 ppm
Conductivity 50 µS/cm
NH30 ppm
Total iron ions (Fe2+ and Fe3+) < 0.2 ppm
Chloride (Cl-) < 1 ppm
H2S 0 ppm
Solid particles < 50 µm
A concentration of ethylene-glycol higher than the 30% can seriously
damage the pump of the ultracool units.
ultrafilter will not accept any warranty for any damage caused by
water that is out of one or more of the above limits. Therefore, if
there is not a total security on the water quality we advise the use
of our product refrifluid. This fluid has been specially designed for
the protection of closed water circuits. Besides this ultrafilter offers
the possibility of doing a basic analysis of a water sample supplied
by the customer.
UC-140 INDIGO 50/60Hz 29.01.03 rev. 0

- -
17
10 Spare parts
10 Spare parts
UC-140 Indigo 50Hz UC-140 Indigo 60Hz
Amount Article number Article number
Compressor 1 0100165000 0104710000
Condenser 1 E3751054 E3751054
Evaporator 1 E5293018 E5293018
Motor fan 1 E5204252 E5204258S
Pump 1 E4521374 E4521442
Water tank 1 E3540026 E3540026
Liquid vessel 1 C210129000 C210129000
Expansion valve 1 0101807000 0101807000
Dryer filter 1 0112095000 0112095000
High pressure safety switch 1 0106437000 0106437000
Low pressure safety switch 1 0110140000 0110140000
Control thermostat 1 E5326003 E5326003
Antifreeze thermostat 1 E5326003 E5326003
Sight glass 1 0107397000 0107397000
Refrigerant gas kg (lb) 14 (31) R-134a R-134a
Level control 1 E4202004 E4202004
Water by-pass 1 E2301002 E2301002
Pump pressure gauge 1 E5544014 E5544022
Compressor contactor 1 E4242022SE4242024S
Pump contactor 1 E4251402S E4251402S
Motor fan contactor 1 E4251402S E4251402S
Pump's circuit breaker 1 E4266034 E4266038
Motor fan's fuse carrier 1 E4221420 E4221418
General switch 1 E4292012 E4292016
On/Off switch 1 E4132102 E4132102
2A Fuse 2 E4221231B E4221231B
6A Fuse 1 E4221232 E4221232
Motor fan fuses 3 E4221232 E4221242
Control transformer 1E4181904S2 E4181930
Pressure transducer 1 E5328008T E5328008T
Speed regulator controller 1 E5328006 E5328006
Speed regulator 1 E5328004 E5323022
UC-140 INDIGO 50/60Hz 22.04.03 rev.1