omi CHW Series Operating instructions

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Recirculating chillers for liquids
Рециркуляционные жи костные
холо ильные установки
CHW 09 to/до CHW 3652
CHO 29 to/до CHO 149
CHG 08 to/до CHG 365
English
Operating and maintenance manual
Русский
Руково ство по эксплуатации и
техническому обслуживанию
O.M.I. srl
Via dell'Artigianato, 34 Fogliano (GO) 34070 ITALY
Tel: [phone] Fax: [phone]
www.omi-italy.it
[e-mail]

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TABLE OF CONTENTS
1. GENERAL USER AND MAINTENANCE MANUAL ......................................................................
1.1 HOW TO USE THIS MANUAL ................................................................................................ 3
1.2 GENERAL DESCRIPTIONS/INTENDED USE ............................................................................. 3
2. GENERAL SAFETY INSTRUCTIONS .......................................................................................
. DESCRIPTION OF THE CHILLER, COMPONENTS AND OPTIONS ............................................ 5
3.1 DESCRIPTION .................................................................................................................... 5
3.2 REFRIGERANT CIRCUIT ...................................................................................................... 5
STANDARD COMPONENTS USED IN THE CHILLER ............................................................................................. 5
OPTIONS – REFRIGERATION CIRCUIT ............................................................................................................. 6
3.3 COOLING MEDIUM CIRCUIT (CONSUMER CIRCUIT) ................................................................ 6
STANDARD COMPONENTS USED IN THE CHILLER ............................................................................................. 6
OPTIONS – HYDRAULIC CIRCUIT .................................................................................................................... 7
SINGLE-CIRCUIT SYSTEM WITH TANK (STANDARD) ......................................................................................... 7
SINGLE-CIRCUIT SYSTEM WITHOUT TANK ....................................................................................................... 8
3.4 ELECTRIC CIRCUIT ............................................................................................................. 8
STANDARD COMPONENTS USED IN THE CHILLER ............................................................................................. 8
OPTIONS – ELECTRIC CIRCUIT ....................................................................................................................... 9
3.5 HOUSING .......................................................................................................................... 9
4. TRANSPORT/ PACKAGING/ STORAGE ............................................................................... 11
4.1 REMOVING THE PACKAGING AND HANDLING THE CHILLER ................................................... 11
4.2 DISPOSAL OF PACKAGING MATERIALS ............................................................................... 12
4.3 STORAGE ........................................................................................................................ 12
5. LOCATION AND INSTALLATION ......................................................................................... 12
5.1 CHOOSING A LOCATION ................................................................................................... 12
5.2 ASSEMBLY (CONNECTIONS) .............................................................................................. 13
CONNECTION TO THE REFRIGERANT CIRCUIT (CONSUMER CIRCUIT) ............................................................... 3
CONNECTION TO THE ELECTRICITY MAINS .................................................................................................... 4
6. OPERATION ....................................................................................................................... 15
6.1 CHECK LIST FOR THE INITIAL START-UP OF WATER RECIRCULATING CHILLERS ..................... 15
WATER REQUIREMENTS .............................................................................................................................. 5
CHECKLIST FOR CHW 09 TO CHW 3652 ........................................................................................................ 6
6.2 CHECKLIST FOR STARTING UP OIL RECIRCULATING CHILLERS ............................................. 18
OIL REQUIREMENTS ................................................................................................................................... 8
CHECKLISTE FOR CHO 29 TO CHO 49 ......................................................................................................... 9
6.3 CHECK LIST FOR COMMISSIONING GLYCOL RECIRCULATING CHILLERS ................................. 19
REQUIREMENTS FOR THE WATER-GLYCOL MIXTURE ....................................................................................... 9
CHECKLIST FOR CHG 08 TO CHG 365 ........................................................................................................... 20
6.4 OPERATING SETTINGS FOR THE ELECTRONIC CONTROLLER ................................................. 21
CONTROLLER TYPE “A” (CHW TO CHW 36; CHG 08) ................................................................................... 22
CONTROLLER TYPE “B” (CHW 29 TO CHW 602; CHO 29 TO CHO 49; CHG 24 TO CHG 40) ............................... 23
CONTROLLER TYPE “C” (CHW 682 TO CHW 3652; CHG 80 TO CHG 365) .......................................................... 24
6.5 SHUTTING DOWN THE CHILLER ......................................................................................... 25
SWITCHING ON/OFF IN DAILY OPERATION .................................................................................................... 25
TEMPORARY DECOMMISSIONING ................................................................................................................. 26
DECOMMISSIONING FOR TRANSPORT PURPOSES ........................................................................................... 26
7. MAINTENANCE ................................................................................................................... 26
7.1 MAINTENANCE OPERATIONS ............................................................................................. 26
7.2 DAILY RECORD ................................................................................................................ 27
8. DISPOSAL .......................................................................................................................... 27
9. MALFUNCTIONS/TROUBLESHOOTING ............................................................................... 28
9.1 POSSIBLE ALARM SIGNALS AND THEIR RECTIFICATION ....................................................... 28
CONTROLLER TYPE “A” (CHW TO CHW 36; CHG 08) ................................................................................... 28
CONTROLLER TYPE “B” (CHW 29 TO CHW 602; CHO 29 TO CHO 49; CHG 24 TO CHG 40) ................................ 30
CONTROLLER TYPE “C” (CHW 682 TO CHW 3652; CHG 80 TO CHG 365) .......................................................... 32
10. FEATURES AND TECHNICAL DATA/MERKMALE UND TECHNISCHE DATEN .......................... 68
10.1 TECHNICAL FEATURES / TECHNISCHE DATEN ..................................................................... 68
10.2 PUMP AND TANK CHARACTERISTICS / PUMPE UND TANK MERKMALE ..................................... 69
10.3 COMPONENTS WITH A WEIGHT OF MORE THAN 20 KG/KOMPONENTEN MIT MEHR ALS 20 KG ... 70
11. DIAGRAMS / DIAGRAMME ................................................................................................. 71
11.1 LEGEND / LEGENDE ......................................................................................................... 71
12. REGULATION ON PRESSURE EQUIPMENT / DRUCKGERÄTEREGELUNG ............................... 7
1 . DECLARATION OF CONFORMITY / KONFORMITÄTSERKLÄRUNG ........................................ 74
14. PROGRAMMED MAINTENANCE REGISTER / REGELMÄSSIGES WARTUNGSTAGEBUCH ........ 75
15. INDIVIDUAL SPECIFICATION / INDIVIDUELLE SPEZIFIKATION ....................................... 76

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1. GENERAL USER AND MAINTENANCE MANUAL
1.1 HOW TO USE THIS MANUAL
This operating and maintenance manual is intended for specialist personnel who are responsible for the
installation, commissioning and operation of cooling water recirculating chillers of the type CHW, oil recir-
culating chillers of the type CHO and glycol recirculating chillers of the type CHG. The term “chiller” is
used as a general name for these appliances.
This operating and maintenance manual is an essential constituent of the chiller. Every user, operator
and service technician is required to carefully read the information and instructions contained in this op-
erating and maintenance manual – particularly those that affect safety – before transporting, installing,
using, performing any maintenance on or disposing of the chiller.
The owners and operators of the chiller shall ensure that all work to be carried out on the chiller is only
undertaken by personnel with suitable specialist qualifications.
The operating and maintenance manual is divided into two sections that contain a detailed description of
the three type series CHW, CHO and CHG, with their respective standards and with additional information
on the customer-specific design and the respective model of your chiller, wherever this differs from the
standard model. Here you will find information such as the circuit diagram for the chiller you have cho-
sen.
1.2 GENERAL DESCRIPTIONS/INTENDED USE
The CHW, CHO and CHG chillers have been designed for the purpose of keeping a certain quantity of
cooling medium, e.g. water, water-glycol moisture or oil constantly within certain temperature limits (op-
erating range), with the aid of a technical cooling process. The most commonly used cooling medium,
also called the “consumer refrigerant” is mains water. This operating manual uses the general term cool-
ing medium. However, the cooling medium and the materials used in the circuit must be compatible with
one another. It is therefore necessary to check and ensure before commissioning that the cooling me-
dium is suitable for the intended purpose.
These chillers are recommended for use in the recirculated chilling of liquids (cooling media) in industrial
and commercial applications, particularly in cases where specific and constant temperatures are required,
such as in mechanical engineering, in the plastics industry, in surface technology and in the laser indus-
try.
Explanation of the product designations CHW, CHO and CHG:
CHW recirculating water chiller
CHO recirculating oil chiller
CHG recirculating glycol chiller
2. GENERAL SAFETY INSTRUCTIONS
SYMBOLS USED ON THE CHILLER OR IN THE MANUAL:
Chiller
Cooling medium inlet
WARNING OF DANGER
Read the instructions carefully, dis-
connect the electricity supply and re-
lease the pressure from any pressur-
ized components before carrying out
any maintenance work on the chiller.
Cooling medium outlet
Direction of rotation for fan/pump
Operating and maintenance manual: warning and hazard symbols
GENERAL WARNING – GENERAL HAZARD:
General warning – general safety hazard for people and property!
DANGER – ELECTRICAL CURRENT:
Danger of an electrical accident occurring while carrying out work on parts of the chiller and the
systems/equipment connected to it while they are connected to the electricity supply!

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DANGER – HOT SURFACES/HIGH TEMPERATURE OF COOLING MEDIUM:
Danger of burns due to high temperatures in the hot parts of the chiller
and/or the cooling media it contains!
DANGER – MOVING PARTS:
Danger of injuries due to contact with the moving parts of the chiller!
DANGER – EYE INJURIES:
Danger of eye injuries resulting from the use of compressed air or from fluid particles during
cleaning work!
All work connected with the installation, operation and maintenance of the chiller must be performed in
accordance with the instructions contained in the operating and maintenance manual and in compliance
with the legal provisions that apply in the country where the device is installed. All cleaning/maintenance
work that requires access to the chiller has to be performed by qualified specialist personnel who have
been informed of the necessary precautions to be taken. Read the operating and maintenance manual
carefully before performing any work on the device. The chiller has been designed and manufactured in
such as way as to comply with the standards that apply in the respective country. Should the chiller be
used for the incorrect purpose or not in accordance with the operating and maintenance manual, the
manufacturer cannot be held responsible.
THE FOLLOWING POINTS MUST BE OBSERVED BEFORE COMMISSIONING AND WHILE OPERATING THE
CHILLER:
Familiarize yourself with all the operating controls.
The chiller may be used solely for the intended purpose.
Make sure that all the working limits indicated in the operating and maintenance manual are
observed.
 Use protective devices to check electrical insulation. Do not carry out any work on any parts
of the equipment that might be live with wet clothing, hands or feet.
 Check at regular intervals whether the safety and control devices of the chiller are functioning
properly.
Never hit the pipes located on the inside of the chiller with objects of any kind.
Any maintenance operations not mentioned in the operating and maintenance manual must
not be carried out by personnel without the manufacturer’s prior written authorization if any
equipment components are under pressure.
 Never spill or pour any cooling medium into the environment as this may cause damage to
health. Before the chiller is resold, the cooling medium must be drained from the chiller using
suitable equipment. Please contact customer service of the nearest dealer in this connection.
 The side panels of the chiller must not be removed unless this is absolutely necessary. Even if
the side panels are only partially removed, isolate the chiller from the electricity supply and
affix a sign to the control panel bearing the warning “Maintenance work on chiller in pro-
gress”. Replace the side panels as quickly as possible.
The components of the chiller must not be modified in any way.
 Bypassing the electrical protective devices may result in overloading of the chiller.
The chillers are exclusively designed for cooling the types of cooling medium listed in the following table.
CHW series: Water with ethylene glycol added as anti-freeze, where necessary. If glycol is used,
the minimum limit of 20% and maximum limit of 25% should be observed.
CHO series: Lubricating or hydraulic oil with a viscosity of 10 cST or higher with a temperature
limit varying according to the oil type.
CHG series: Water with ethylene glycol added as anti-freeze with a minimum of 20% and a maxi-
mum of 25% applying to chillers with a standard configuration.
The maximum operating conditions (temperature of the cooling medium and room temperature) and the
permissible features for the cooling medium are contained in Section 5 of this manual.
When handling liquids intended for a special purpose, e.g. health or food applications, please
check the contractually defined technical specifications. Cooling medium with a high content of
solid matter may not be used with these chillers.
Possible risks:
CAUTION: The chiller is equipped with a main switch.
The authorized installation technician must ensure that the chiller has been connected to the
electricity mains in accordance with the standard EN 60204 and must ensure compliance with all
other applicable national standards.
Fire:
According to European Standard EN 378-2, these chillers may be equipped with a safety valve for drain-
ing cooling medium.

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The electricity supply must be disconnected in the event of fire. Fire extinguishers or fire extinguishing
systems filled with powder, foam or carbon dioxide should be used by preference. The chiller may also be
cooled with nebulized water. The use of water in large quantities must be avoided because if there is
leakage of refrigerant, the resulting chemical reaction – no matter how slight – may have a corrosive ef-
fect.
In any case, it is necessary to reduce the ambient temperature and/or that of the chiller and wait for the
temperature to fall before carrying out any work on the unit.
You are advised to include this device in your Fire Prevention Plan and Factory Safety Plan.
Make sure that suitable precautions have been implemented to avoid and combat any possible risks.
In the event of refrigerant leakage:
The refrigerant may lead to asphyxiation if it is inhaled in high concentrations. It is necessary to ensure
adequate ventilation for the room in which the chiller is installed.
Be sure to the read the safety data sheet with the relevant values and warnings.
Excessive pressure on the cooling medium side:
The chiller is equipped with safety devices on the cooling medium side.
These have to be mounted by the installation technician. The installation of any such devices must com-
ply with the applicable national standards and be carried out in accordance with the limits given in this
manual.
Depletion of the ozone layer:
The use of HFC refrigerants, in compliance with Regulation CE/842/2006, reduces damage to the ozone
layer and minimizes the greenhouse effect.
. DESCRIPTION OF THE CHILLER, COMPONENTS AND OPTIONS
.1 DESCRIPTION
The chiller is supplied ready for connection. It consists of a housing, a fully hermetically sealed cooling
medium circuit, the refrigerant circuit, the cooling medium circuit and the electrical circuit, including all
control and monitoring devices which are required for fully automatic operation. The selected and used
cooling medium must comply with environmental standards and the legal provisions.
.2 REFRIGERANT CIRCUIT
STANDARD COMPONENTS USED IN THE CHILLER
The preceding abbreviations indicate the position in the drawings.
Not all components are contained in all models.
C– Compressor
Scroll-type compressor of fully hermetic design with integrated bimetal switch and oil sight glass.
Semi-hermetic compressor:
Semi-hermetic compressor with integrated bimetal switch and oil sight glass.
Reciprocating piston compressor:
Reciprocating piston compressor, fully hermetic with integrated bimetal switch and, in most models, an
oil sight glass.
CND – Condenser / Condenser safety grating
Condenser as fin-type heat exchanger consisting of copper pipes with aluminium fins. The safety grating
for the housing protects the condenser on the inside against mechanical damage. The positioning of the
condenser avoids any additional heat load on the components located inside the housing.
EVA – Evaporator
Insulated shell tube heat exchanger or stainless steel plate heat exchanger.
HP – High-pressure pressostat
The high-pressure pressostat protects the refrigeration circuit of the chiller against excessively high oper-
ating pressure (high-pressure fault).
In this kind of fault, the high-pressure pressostat switches the compressor off when the preset limit is ex-
ceeded. The compressor cannot be started up again until the preset differential pressure has been
reached and the Reset button located inside the chiller has been pressed. The fault is displayed on the
control unit.
LP – Low-pressure pressostat
The low-pressure pressostat protects the refrigeration circuit of the chiller against excessively low operat-
ing pressure (low-pressure fault).

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When this kind of fault occurs, the low-pressure pressostat switches the compressor off when the preset
limit is undershot. The compressor starts up automatically if when the permitted pressure ratios have
been re-established between the high and low pressure sides via the internal pressure compensation sys-
tem. The fault is displayed on the control unit while it persists.
Manometer in the refrigeration circuit
MHP – High-pressure manometer:
The manometer shows the pressure on the high-pressure side within the refrigeration circuit. The dis-
play is located on the connection side, above the cooling medium connections.
MLP – Low-pressure manometer
The manometer shows the pressure on the low-pressure side within the refrigeration circuit. The display
is located on the connection side, above the cooling medium connections.
PV – Pressostatic fan control
The condensation pressure is controlled by pressostatic activation and deactivation of the fans. This type
of control allows adaptation to different operating conditions at constant condensation temperatures.
R – Crank case heating
The electrical crank case heating is activated after the main switch has been turned on. It protects
against a refrigerant accumulating in the compressor. This avoids faults during the compressor start-up
phase at low ambient temperatures.
V – Ventilator (fan)
Axial: Low-noise axial ventilator (maintenance-free).
Radial: Low-maintenance radial ventilator for connection to an air duct on the customer’s premises.
Injection process
a. Capillary injection (up to cooling capacities of approx. 2.5 kW).
The refrigerant is injected via a defined capillary.
b. VE – Expansion valve (from cooling capacities of approx. 2.5 kW)
Thermostatic valve that limits the evaporation pressure to a maximum.
(MOP; maximum operating pressure).
Piping (cooling system)
Closed pipe system made of copper tubing, including fittings. Supplied as required with additional fittings
such as non-return valves, filter drier, sight glass and service connections.
OPTIONS – REFRIGERATION CIRCUIT
Condenser air filter, aluminium (reusable)
The condenser air filter protects the condenser against dirt. It is easy to clean and can be reused over a
long period of time.
IAF – Air filter monitoring
Heavy contamination of the air filter is indicated by an acoustic warning signal visible on the controller,
which is triggered by the pressostat.
Variable fan speed control
The condensation pressure is kept at a constant level by fans with a speed control and is particularly
suitable for use at extremely low ambient temperatures.
Hot gas bypass regulating device
The bypass pipe with solenoid valve and throttle device is used when there are exact requirements on the
constancy of the cooling medium outlet temperature or when there are high load fluctuations.
Water-cooled condenser (instead of air-cooled condenser)
This consists of a plate heat exchanger or a shell tube heat exchanger that uses existing cooling water to
condense the refrigerant. It replaces the finned pack heat condenser and the fan.
This cools and recondenses the refrigerant. The cooling water requirement can be adjusted according to
the condensation pressure with a pressostatic control valve.
. COOLING MEDIUM CIRCUIT (CONSUMER CIRCUIT)
STANDARD COMPONENTS USED IN THE CHILLER
MF –Manometer for the cooling medium
In chillers with an integrated pump, the manometer indicates the pressure at the cooling medium outlet.
In chillers with no integrated pump, the manometer indicates the pressure at the cooling medium inlet.
P – Pump
A single-stage or multi-stage centrifugal pump of horizontal or vertical design is used according to the
type of model.

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Differential pressure monitor
The differential pressure monitor protects the plate heat exchange of the chiller against excessively low
flow rates and hence against damage caused by ice formation.
OPTIONS – HYDRAULIC CIRCUIT
BP – Automatic bypass / Overflow valve
The overflow valve is intended to guarantee a minimum throughput in the cooling medium circuit. This
protects the evaporator and the pump.
BPM – Manual bypass
This type of bypass can be used to manually adjust the minimum throughput in the cooling medium cir-
cuit.
CAA – Automatic cooling medium feed via a float valve
The cooling medium is filled up automatically by the float valve if the level in the tank falls below a mini-
mum.
EV 1 – Solenoid valve 1 (connect without current) in return circuit
These valves should be used in open systems when the consumers are installed on a higher level. This is
generally used as a valve combination with VNR (see below).
FL – Flow controller
The flow controller located in the cooling medium inlet monitors the flow in the cooling medium and con-
sumer circuit. It switches the cooling system off if the throughout falls below a minimum.
LVE – Flow switch (systems open to the atmosphere with tank)
The flow switch is located in the tank and monitors the cooling medium level.
If the water level falls and reaches the minimum value, the cooling system and the pump(s) are switched
off. The chiller cannot be switched on again until the cooling medium has been filled up to the MAX mark
on the level display.
RA – Tank heating
The tank heating warms the cooling medium in the tank. It is used to achieve the optimum operating
temperature within a short time if there is a low ambient temperature and no process heat is being
added.
TD – Digital thermometer in return circuit (systems with single and dual circuit)
The digital thermometer shows the inlet temperature of the cooling medium.
VNR – Non-return valve in the supply line
These valves are used in open systems when the consumers are positioned at a higher level and prevent
uncontrolled flow of the cooling medium back into the tank when the pump is stationary. They are gener-
ally used in combination with a solenoid valve (EV, see above).
Dirt trap
If there is a risk of the cooling medium becoming contaminated by solids with a diameter > 1 mm during
operation, a dirt trap with an appropriate mesh width has to be used. This should preferably be fitted
outside of the chiller so that it can be cleaned easily. It is important to note the flow direction. The dirt
trap must be cleaned at regular intervals after commissioning the chiller, or as required.
Pump alternatives
A pump is provided as standard and supplies a pressure of 2 to 3 bar at the defined nominal flow rate.
Other pumps can of course be selected according to the project. Depending on the pressure and volume
it may be necessary to carry out adjustments to the system characteristics with the aid of control valves.
SINGLE-CIRCUIT SYSTEM WITH TANK (STANDARD)
The cooling medium circuit has been designed as system open to the atmosphere. The circuit consists of
the following components:
pump of horizontal or vertical design,
tank, open to the atmosphere, thermally insulated with draining facility, optical filling level indica-
tor and cover to prevent contamination of the cooling medium.
piping system consisting of copper or plastic pipes with manometer and probe connection for the
operating thermostats.
The volume of cooling medium in the tanks is a contributory factor to maintaining the constancy of the
cooling medium outlet temperature. The pump conveys the cooling medium within the circuit out of the
tank to the consumer and then back into the tank via the evaporator.

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Legend:
1 Compressor
2 Condenser
3 Expansion valve
4 Evaporator
5 Pump
6 Consumer
7 Tank
SINGLE-CIRCUIT SYSTEM WITHOUT TANK
The cooling medium circuit is designed as a single-circuit system without tank. The pump conveys the
cooling medium inside the circuit through the evaporator and through the consumer.
The cooling medium in cooled inside the evaporator. The circuit consists of the following components:
pump of horizontal or vertical design,
piping system consisting of copper or plastic pipes with manometer and probe connection for the
operating thermostats and the digital temperature display.
If designed as a system closed to the atmosphere, the external circuit must be provided with
venting connections and with pressure compensation tank if required!
.4 ELECTRIC CIRCUIT
STANDARD COMPONENTS USED IN THE CHILLER
ALR – Composite Failure Report
The composite failure report summarizes all fault messages from the compressor, the pump(s), fan(s) of
the high-pressure and low-pressure pressostats, the flow monitor as well as the breakage of probes.
Voltage-free series connection of this composite report takes place at the terminals in the switch cabinet
(see circuit diagram in the Annex).

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IG – Main switch
The chiller carries no current after it has been turned off with the main switch. The switch is located on
the door of the switch cabinet.
MTC – Motor protection switch for compressor
If the motor current increases beyond the set value or if there is a short circuit, the motor protection
switch turns off and interrupts the current supply. The motor protection switch has to be turned on
manually after the cause of the malfunction has been eliminated. The motor protection switch is located
in the switch cabinet.
MTP – Motor protection switch for pump
If the motor current increases beyond the set value or if there is a short circuit, the motor protection
switch turns off and interrupts the current supply. The motor protection switch has to be turned on
manually after the cause of the malfunction has been eliminated.
The motor protection switch is located in the switch cabinet.
ROO – Remote control
The chiller can be switched off by the consumer or from a control room with the aid of an external con-
tact. When this occurs, the main switch remains permanently switched on.
QE – Switch cabinet
The switch cabinet contains all the electrical components and safety devices.
TLT – Temperature controller
Temperature control and regulation is carried out by the temperature controller of the chiller in accor-
dance with the preset value.
The temperature controller with digital display is integrated in the door of the switch cabinet. Fault mes-
sages are displayed on the temperature controller by means of codes.
OPTIONS – ELECTRIC CIRCUIT
Connecting cable with CEE plug
A ready-to-use mains cable is supplied with 6m oilflex cable and CEE plug 4-pole (3P+PEN) or 5-pole
(3P+N+PE).
Compressor winding protection
Depending on the compressor type, the protection is provided either by Klixon (bimetal strip) or by a
temperature probe. If the maximum permissible winding temperature is attained, the motor protection
switch turns off the compressor.
.5 HOUSING
Legend for all the following housing versions:
1 Level
2 Power supply
3 Temperature controller
04I Cooling medium inlet
04O Cooling medium outlet
05I Cooling water condenser inlet (*)
05O Cooling water condenser outlet (*)
(*) in water-cooled chillers
MODELS: CHW 09
MODELS
A
B
H
C
D
E
F
G
I
L
M
(Ø)
CHW 09
375
450
630
/
580
/
/
/
80
55
/
1/2”

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MODELS: CHW 11, CHW 21, CHW 26, CHW 36; CHG 08
MODELS
A
B
H
C
D
E
F
G
I
L
M
(Ø)
CHW
11, 21, 2
6
/
CHG
08
575
445
540
/
490
/
/
/
80
56
608
½”
CHW 36
575
445
640
/
490
/
/
/
80
56
608
½”
MODELS: CHW 29, CHW 39, CHW 56, CHW 67; CHO 29, CHO 39, CHO 56, CHO 67; CHG 24, CHG 30,
CHG 45
MODELS
A
B
H
C
D
E
F
G
I
L
M
(Ø)
CHW 29, 39, 56, 67 / CHO 29
580
650
920
845
419
80
583
80
/
82,5
1036
¾”
CHO 39, 56, 67
580
650
920
845
419
80
583
80
/
82,5
1036
1
”
CHG 24, 30, 45
580
650
920
845
419
80
583
80
/
82,5
1041
¾”
MODELS: CHW 97, CHW 130, CHW 149; CHO 97, CHO 130, CHO 149; CHG 75, CHG 100

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MODELS
A
B
H
C
D
E
F
G
I
L
M
(Ø)
CHW 97, 130
760
760
133
5
1250
767
100
972
100
/
84
1445
¾”
CHO 97, 130
760
760
1335
1250
767
100
972
100
/
84
1445
1”
1/2
CHG 75
760
760
1335
1250
767
100
972
10
0
/
84
1445
¾”
CHW 149 / CHG 100
760
760
1385
1300
767
100
972
100
/
84
1510
¾”
CHO 149
760
760
1385
1300
767
100
972
100
/
84
1510
1”
1/2
MODELS: CHW 162 to CHW 1202; CHG 140 to CHG 365
MODELS
A
B
H
C
D
E
F
G
I
L
M
(Ø)
CHW 162, 192, 242, 292, 372
CHG 180, 240 1325 760 1525 1400 300 300 635 300 / 84 / 1”
CHW 432 to 752
CHG 225, 280, 365 1325
1520 1525 1400 300 300 635 300 / 84 / 1½”
CHW 1002
1325
2280
152
5
1400
300
300
6
35
300
/
84
/
1½”
CHW 1202
1325
3040
152
5
1400
300
300
6
35
300
/
84
/
2”
MODELS: CHW 1452 to CHW 3652
MODELS
A
B
H
C
D
E
F
G
I
L
M
(Ø)
CHW
1452,
1802 1525 3990 2170 2060 381
100
/
/
200
310
/
3”
CHW
2052
1525
3990
217
0
2060
381
100
/
/
200
310
/
3”
CHW 2552
1525
3990
2170
2060
381
100
/
/
200
310
/
3”
CHW 3152
1525
4990
217
0
2060
381
100
/
/
200
310
/
3”
CHW
3652
1525
4
990
217
0
2060
381
100
/
/
200
310
/
3”
4. TRANSPORT/ PACKAGING/ STORAGE
4.1 REMOVING THE PACKAGING AND HANDLING THE CHILLER
Each chiller is supplied in a reinforced carton on a wooden pallet. The chiller must be kept in an upright
position at all times. NOTE: Tilting the chiller may cause serious damage!
Procedure:
* Remove the strapping from the carton. Always wear safety gloves when using scissors
or other tools to cut the straps.
* Remove the carton.
* Raise the chiller using suitable lifting gear.
NOTE: If the chiller is fitted with eyebolts, these must be used for lifting it in accordance with the ap-
plicable safety standards.
If the chiller is not fitted with eyebolts, the lifting gear must be appropriate for the weight of the
chiller, as indicated on the identification plate and in the Annex.

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* Remove the pallet (if present).
* Place the chiller in the desired location.
* Remove the operating manual, accessories and key from the chiller.
CHW 97 - CHW 3652
4.2 DISPOSAL OF PACKAGING MATERIALS
We recommend that you keep the original packaging for the chiller in case it has to be transported to an-
other location or sent to a service centre. In any case, the waste packaging material must be deposited
with the responsible waste disposal companies.
4. STORAGE
The chiller must be stored in rooms protected from weather-related influences. These rooms must be dry
and have a temperature range of between +5 and +50°C.
If the chiller is stored for longer than 12 months, please contact the manufacture before
starting up the chiller again to check the condition of the machine parts, particularly the elec-
trical components.
See Chapter 6.5.2 (Temporary decommissioning).
5. LOCATION AND INSTALLATION
5.1 CHOOSING A LOCATION
Install the chiller in a protected dry area, free of fumes, dust or flammable vapours that is not
subject to an explosive hazard. The atmosphere must be free of any constituents that may im-
pair the proper functioning of the chiller.
A suitable area must be found in which a temperature of not less than +2°C and definitely not more than
+40°C can be guaranteed at any time of the year while the machine is operating. If you wish to operate
the chiller at ambient temperatures of less than +2°C or more than +40°C, please contact the manufac-
turer in connection with the necessary adaptations.
We recommend that appropriate ventilation should be provided. Operating the chiller heats up the area in
which it is installed. This applies particularly to chillers with a standard air-cooled condenser.
So as not to impair the cooling capacity of the chiller, we recommend protecting it against direct sunlight.
You should avoid connecting the axial ventilators to air ducts as they do not have sufficient compression.
Higher ambient temperatures than those given as a reference value in the data sheet reduce the cooling
capacity.
The chiller should be installed on a horizontal and level surface that is capable of absorbing the compres-
sive load of the chiller. Larger chillers have holes at the ends of the supporting rails so that they can be
fastened to the floor.
When the chiller is installed outside, it should be protected against any atmospheric influences. Please
consult the manufacturer for further details.

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Position the chiller so that the instrument displays can be read easily and the controls can be easily ac-
cessed.
Allow sufficient space for the possible installation of further components.
There must be sufficient free space above the chiller to ensure that air can flow freely to cool the con-
denser.
(Sample illustration. See the corresponding letters for the other versions. B is always the front side)
Models A (m) B (m) C (m) D (m) E (m) LOCATION
CHW 09 to 36, CHG 08 1 1 1 1 1 Indoors
CHW 29 to 67, CHO 29 to 67,
CHG 24 to 45
1 1 1 1,5 1
Sheltered outdoor
location
CHW 97 to 149, CHO 97 to 149,
CHG 75 to 100
1 1 1 2 1
CHW 162 to 1202, CHG 140 to 365 1 1 1 3 1 Outdoors (shelter
recommended)
CHW 1452 to 3652 1 2 1 4 2
5.2 ASSEMBLY (CONNECTIONS)
CONNECTION TO THE REFRIGERANT CIRCUIT (CONSUMER CIRCUIT)
All work may only be carried out by specialist personnel!
Procedure: -In closed systems, make sure that the maximum obtainable cooling medium pressure in
the supply line does not cause a higher pressure level than the maximum permitted for
the chiller.
-Check the cleanliness of the supply line and the piping system to be connected.
-Connect the chiller with the consumer circuit; the identification of the joints (cooling me-
dium inlet/outlet) is indicated on the chiller by means of the symbols described in the in-
troduction to the manual.
-Make all the connections, without rotating the sleeves located on the hose.
The cooling medium circuits of the Series CHW and CHG with tank are open to the atmosphere
as standard!
Use piping, connections and fastening components with a cross-section to match the capacity of the
chiller and the possible volume flow. This should not be smaller than the diameter of the chiller connec-
tions.
In the case of rigid connections, check during the initial start-up of the chiller that it is not subject to any
vibrations that might endanger the integrity of the components.
We also recommend that you should plan to install the following system components:

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♦ A bypass system with suitable valves upstream and downstream of the chiller. This is intended to
allow use of the consumer circuit if you have to remove the chiller from the circuit, switch it off or
use it in different ways at the same time .
♦ A pipeline system with integrated filter near the chiller to protect the pump against solid matter
and avoid deposits on the heat exchangers. The recommended mesh width for the chillers is 25µ
with a maximum pressure loss at the filter of 1 bar. The use of a filter with a mesh width of 60µ is
particularly suitable for chillers of the CHO series if they are fitted with a gear pump, so as to
avoid unusual wear of the component.
♦ In the models without flow monitoring, we suggest that you should install such a component if
the system exhibits losses or very high cooling medium consumption due to evaporation or inter-
vention by the operator. A further reason may be triggering of the solenoid valve to shut down
the system. The flow meter may trigger an alarm and enable immediate operator intervention.
♦On no account may the total pressure loss of the system exceed a value above that of the pump
performance.
♦Another option for directly filling the tank involves attaching a T-fitting to the cooling medium
outlet fitting in order to connect the cooling medium circuit with a supply pipe. This is used to fill
the chiller. We also recommend connecting a valve to the supply pipe in order to stop the flow
when the tank is full or to restart the flow as soon as a top-up is necessary.
A Male-male fitting
B From the supply line
C To the consumer cooling circuit
D T-fitting
E Connecting piece to cooling
medium outlet
Fig.1
CONNECTION TO THE ELECTRICITY MAINS
The properties of the electricity mains (size, protection system, earth connection) must comply with the
legislation applying to the electrical properties of the chiller in the country in which it is installed.
The general regulations pertaining to installation are listed below.
The electrical installation may only be carried out by qualified personnel!
The mains connection should be established with a rubber-sheathed cable connected to a TN-C system
with direct earthing.
2 0 V version (1 phase):
Connection with a single-phase, three-wire system (1/N/PE AC). The phase conductor and the neutral
conductor must be connected directly to the main switch of the chiller.
The protective earth conductor must be connected to the earthing point of the chiller.
400 V version ( phase):
Connection with a three-phase, four-wire system (3/PEN AC). The three-phase conductor must be con-
nected directly to the main switch of the chiller. No neutral conductor is used. The PEN must be con-
nected to the earthing point of the chiller.
If different mains voltages and frequencies are available, the country-specific features must be observed.
Make sure that the mains voltage and the frequency match the data on the identification plate of the
chiller and agree with those in the table in the supplement and that the permitted values are not ex-
ceeded. Check the mains for correct values and test the function of the earthing and protection systems.

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15
Install a general isolating switch for the electricity mains close to the chiller. The connecting circuit for the
chiller must be equipped with a circuit breaker and residual current protective device.
You can find information on the electrical power input values for the chiller in the supplement.
Before you connect the chiller to the mains, make sure that the general isolating switch disconnects the
chiller from the electricity mains.
Pass the wires in the flexible polymer cable gland in the control panel (see photo for position) to connect
the power cable. Feed the connecting lead through the aperture in the rear plate (CHW 29 - CHW 149) on
the base of the chiller. Lay the cable on the upright up to the gland on the base of the switch cabinet
(CHW 162 - CHW 3652). Inside the switch cabinet lay the cable in the installation duct up to the main
switch, where it is connected directly.
Check that the screws on the terminal clamps are firmly seated!
6. OPERATION
6.1 CHECK LIST FOR THE INITIAL START-UP OF WATER RECIRCULATING
CHILLERS
After extraordinary maintenance work or after turning off the main switch for more than 1 hour, each
start-up should be treated as an initial start-up.
The initial start-up calls for a number additional checks to ensure safe and reliable performance of the
system.
Before start-up :
Make sure that the pump motor is not blocked: simply move the fan of the pump motor one
quarter of a turn.
WATER REQUIREMENTS
Quality:
Standard chillers require water of mains water quality. If no water of mains quality is available, please
contact the manufacturer for advice.
If additives are being used, make sure that these are suitable for use with the materials and components
of the chiller. Note that the quantity of additives may impair the performance of the chiller, e.g. due to
unsuitable viscosity).
The pipelines of the water circuit may be made of copper, stainless steel or plastic.
General operating conditions:
In standard recirculating chillers the outlet temperature of the cooling medium must be between +5°C
and +20°C. If temperature values of more than +20°C are required for the preset temperature, please
contact the manufacturer for appropriate adaptations.
Conditions during commissioning:
The inlet temperature of the cooling medium should not be more than +25°C.
If temperature values of less than +5°C apply to the preset temperature, antifreeze must be used.
Holes for feeding through the power cable
Cable inlet

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The glycol must contain anti-corrosion additives. In the standard configuration, the CHW series, ethylene
glycol in concentrations of 20% up to a maximum of 34% may be used for minus temperatures down to
–10°C. Add antifreeze for ambient temperatures of approx. ±0°C.
When antifreeze is used, it is important to make sure that the current consumption remains within the
data indicated on the identification plate on the motor.
CHECKLIST FOR CHW 09 TO CHW 652
(CHW 09)
1) Fill the collection tank. Open the tank cap and fill the tank (using a T-fitting if necessary) while watching the
level indicator (refer to Fig. 1, Point 5.2.1).
2) Move the main switch of the chiller to position “1”.
3) Top up the tank again if too much cooling medium has flowed out of the shut-off valve.
Controller Type “A”, see 6.4 (CHW 11 to CHW 6)
1) Remove the lid panel and the two side panels.
2) Fill the collection tank. Open the tank cap and fill the tank (using a T-fitting if necessary) while watching the
level indicator (refer to Fig. 1, Point 5.2.1).
3) Open the filler screw on the pump head.
4) Tighten the screw again when only cooling medium flows out.
5) Open the shut-off valve.
6) Move the main switch of the chiller to position “1”. The display will show “OFF” and the pump will start up.
7) Top up the tank again if too much cooling medium has flowed out of the shut-off valve.
8) After a few minutes carefully open the filler screw again in order to remove any residual air. Tighten the screw
again afterwards.
9) Replace the upper lid panel and the two side panels.
10) Start up the compressor by pressing the button for 3 seconds.
11) Wait until the chiller has attained the operating conditions. This is indicated when the actual temperature
shown in the display matches the preset target temperature.
12) When the chiller is within the operating conditions set by the manufacturer, check whether the electrical ab-
sorption of the chiller agrees with the data indicated on the identification plate and with those contained in the
table in the supplement.
Controller Type “B”, see 6.4 (CHW 29 to CHW 67)
1) Remove the front plate and the two side panels.
2) Fill the tank through the connection on the top of the chiller , or using a T-fitting if necessary, while watching
the level indicator (refer to Fig. 1, Point 5.2.1).
3) Open the filler screw on the pump head.
4) Tighten the screw again when only cooling medium flows out.
5) Open the shut-off valve.
6) Open the switch cabinet with the key supplied (fastened to the main switch when the chiller is delivered).
7) Ensure that the motor protection switches (“MTC” and “MTP”) are in position “0”.
8) Fill the tank to the maximum (upper arrow, level indicator is located on the bottom right of the frame). See
Section 6.1.1 (Water requirements).
9) Move the motor protection switches “MTC” and “MTP” to position “1”.
10) Make sure that the water is able to circulate adequately. It the circuit might be interrupted by something such
as a valve, electrical valve, a filter or anything else, a by-pass circuit (automatic overflow valve) must be in-
stalled in order to prevent damage to the pump.
11) Lock the switch cabinet with the key.
12) Move the main switch of the chiller to position “1” (the temperature of the cooling medium appears on the
display).
Never touch any part of the refrigerant circuit when the chiller is running!
13) Start up the compressor by pressing the button for 3 seconds.
14) Because the pump starts up immediately, make sure that the direction of rotation for the pump matches the
direction of the arrow on the casing. If it is rotating in the opposite direction, turn off the main switch of the
chiller immediately and arrange for the polarity of the chiller to be reversed.
15) After a few minutes carefully open the filler screw again in order to remove any residual air. Tighten the screw
again afterwards.
16) Wait until the chiller has attained the operating conditions. This is indicated when the actual temperature
shown in the display matches the preset target temperature.
17) Check whether the pressure shown is within the limits specified for the pump. If not, take appropriate action
to ensure that the pump is running within the specified limits.
18) Check the level in the tank and top up with cooling medium if required.
19) Wait for the compressor to switch on. The compressor symbol will appear on the display (see Section 6.4).
20) Check the inside of the chiller and the piping system for leakage or loose connections.
21) Fit the front panel and the two side panels back onto the casing.
22) Check the preset target value. The chiller is normally factory-set to the temperature required by the cus-
tomer.

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23) When the chiller is within the operating conditions set by the manufacturer, check whether the current uptake
of the chiller agrees with the data indicated on the identification plate and with those contained in the table in
the supplement.
Controller Type “B”, see 6.4 (CHW 97 to CHW 602)
1) Remove the front plate and the two side panels.
2) Open the tank cap and fill the tank (using a T-fitting if necessary) while watching the level indicator (refer to
Fig. 1, Point 5.2.1).
3) Open the filler screw on the pump head.
4) Tighten the screw again when only cooling medium flows out.
5) Open the shut-off valve.
6) Open the switch cabinet with the key supplied (fastened to the main switch when the chiller is delivered).
7) Ensure that the motor protection switches (“MTC” and “MTP”) are in position “0”.
8) Fill the tank to the maximum (upper arrow, level indicator is located on the bottom right of the frame). See
Section 6.1.1 (Water requirements).
9) Move the motor protection switches “MTC” and “MTP” to position “1”.
10) Make sure that the water is able to circulate adequately. It the circuit might be interrupted by something such
as a valve, electrical valve, a filter or anything else, a by-pass circuit (automatic overflow valve) must be in-
stalled in order to prevent damage to the pump.
11) Lock the switch cabinet with the key.
12) Move the main switch of the chiller to position “1” (the temperature of the cooling medium appears on the
display).
Never touch any part of the refrigerant circuit when the chiller is running!
13) Start up the compressor by pressing the button for 3 seconds.
14) Because the pump starts up immediately, make sure that the direction of rotation for the pump matches the
direction of the arrow on the casing. If it is rotating in the opposite direction, turn off the main switch of the
chiller immediately and arrange for the polarity of the chiller to be reversed.
15) After a few minutes carefully open the filler screw again in order to remove any residual air. Tighten the screw
again afterwards.
16) Wait until the chiller has attained the operating conditions. This is indicated when the actual temperature
shown in the display matches the preset target temperature.
17) Check whether the pressure shown is within the limits specified for the pump. If not, take appropriate action
to ensure that the pump is running within the specified limits.
18) Check the level in the tank and top up with cooling medium if required. Fasten the tank cap afterwards.
19) Wait for the compressor to switch on. The compressor symbol will appear on the display (see Section 6.4).
20) Check the inside of the chiller and the piping system for leakage or loose connections.
21) Fit the front panel and the two side panels back onto the casing.
22) Check the preset target value. The chiller is normally factory-set to the temperature required by the cus-
tomer.
23) When the chiller is within the operating conditions set by the manufacturer, check whether the current uptake
of the chiller agrees with the data indicated on the identification plate and with those contained in the table in
the supplement.
Controller Type “C”, see 6.4 (CHW 682 to CHW 1202)
1) Remove the front plate and the two side panels.
2) Open the tank cap and fill the tank (using a T-fitting if necessary) while watching the level indicator (refer to
Fig. 1, Point 5.2.1).
3) Open the filler screw on the pump head.
4) Tighten the screw again when only cooling medium flows out.
5) Open the shut-off valve.
6) Open the switch cabinet with the key supplied (Fastened to the main switch when the chiller is delivered).
7) Ensure that the motor protection switches (“MTC” and “MTP”) are in position “0”.
8) Fill the tank to the maximum (upper arrow, level indicator is located on the bottom right of the frame). See
Section 6.1.1 (Water requirements).
9) Move the motor protection switches “MTC” and “MTP” to position “1”.
10) Make sure that the water is able to circulate adequately. It the circuit might be interrupted by something such
as a valve, electrical valve, a filter or anything else, a by-pass circuit (automatic overflow valve) must be in-
stalled in order to prevent damage to the pump.
11) Lock the switch cabinet with the key.
12) Move the main switch of the chiller to position “1” (the temperature of the cooling medium appears on the
display).
Never touch any part of the cooling medium circuit when the chiller is running!
13) Start up the chiller by pressing the button (LED lights up).
14) Because the pump starts up immediately, make sure that the direction of rotation for the pump matches the
direction of the arrow on the casing. If it is rotating in the opposite direction, turn off the main switch of the
chiller immediately and arrange for the polarity of the chiller to be reversed.

710.1760.00.04-03A 28/11/2012
18
15) After a few minutes carefully open the filler screw again in order to remove any residual air. Tighten the screw
again afterwards.
16) Wait until the chiller has attained the operating conditions; this is indicated when the display shows the preset
working range.
17) Check whether the pressure shown is within the limits specified for the pump. If not, take appropriate action
to ensure that pump is running within the specified limits.
18) Check the level in the tank and top up with cooling medium if required. Fasten the tank cap afterwards.
19) Wait for the compressor to switch on. The compressor symbol will appear on the display (see Section 6.4).
20) Check the inside of the chiller and the piping system for leakage or loose connections.
21) Fit the front panel and the two side panels back onto the casing.
22) Check the preset target value. The chiller is normally factory-set to the temperature required by the cus-
tomer.
23) When the chiller is within the operating conditions set by the manufacturer, check whether the current uptake
of the chiller agrees with the data indicated on the identification plate and with those contained in the table in
the supplement.
Controller Type “C”, see 6.4 (CHW 1452 to CHW 652)
1) Remove the side panels.
2) Open the tank cap and fill the tank (using a T-fitting if necessary) while watching the level indicator (refer to
Fig. 1, Point 5.2.1).
3) Open the filler screw on the pump head.
4) Tighten the screw again when only cooling medium flows out.
5) Open the shut-off valve.
6) Open the switch cabinet with the key supplied (Fastened to the main switch when the chiller is delivered).
7) Ensure that the motor protection switches (“MTC” and “MTP”) are in position “0”.
8) Make sure that the water is able to circulate adequately. It the circuit might be interrupted by something such
as a valve, electrical valve, a filter or anything else, a by-pass circuit (automatic overflow valve) must be in-
stalled in order to prevent damage to the pump.
9) Check the inside of the chiller and the piping system for leakage or loose connections.
10) Move the motor protection switches “MTC” and “MTP” to position “1”.
11) Lock the switch cabinet with the key.
12) Move the main switch of the chiller to position “1” (the temperature of the cooling medium appears on the
display).
Never touch any part of the cooling medium circuit when the chiller is running!
13) Start up the chiller by pressing the button (LED lights up).
14) Because the pump starts up immediately, make sure that the direction of rotation for the pump matches the
direction of the arrow on the casing. If it is rotating in the opposite direction, turn off the main switch of the
chiller immediately and arrange for the polarity of the chiller to be reversed.
Do not carry out any work inside the chiller if the main switch is in the “ON” position!
15) Make sure that the water is able to circulate adequately.
16) Check whether the pressure shown is within the limits specified for the pump. If not, take appropriate action
to ensure that pump is running within the specified limits.
17) Stop the chiller by pressing the button (LED no longer lights up).
18) Check the inside of the chiller and the piping system for leakage or loose connections.
19) Fill the tank up to the maximum.
20) Fasten the tank cap afterwards.
21) Fit the two side panels back onto the casing.
22) Start up the chiller by pressing the button (LED lights up).
23) Wait for the compressor to switch on. The compressor symbol will appear on the display (see Section 6.4).
24) Wait until the chiller has attained the operating conditions. This is indicated when the actual temperature
shown in the display matches the preset target temperature.
25) Check the preset target value. The chiller is normally factory-set to the temperature required by the cus-
tomer.
26) When the chiller is within the operating conditions set by the manufacturer, check whether the current uptake
of the chiller agrees with the data indicated on the identification plate and with those contained in the table in
the supplement.
6.2 CHECKLIST FOR STARTING UP OIL RECIRCULATING CHILLERS
After turning off the main switch for more than 1 hour or after extraordinary maintenance work, each
chiller start should be regarded as an initial start-up.
The initial start-up calls for a number additional checks to ensure safe and reliable performance of the
system.
OIL REQUIREMENTS
Quality:

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19
The oil used for filling the chiller should have a viscosity index in accordance with the standards indicated
in the following table.
CHO Series Tank close to the chiller (max. 2m)
Gear pump (option) with remote tank
(>2m)
Oil/
Outlet temperature ≤
ISO32/
min. +20°C ≤
ISO46/
min. +25°C ≤
ISO68/
min. +30°C ISO10÷ISO68
General operating conditions:
The oil recirculating chiller is designed for cooling medium temperatures of +20°C to +30°C. If the tem-
perature values deviate from these, please contact the manufacturer.
Conditions during commissioning:
The use of oil with a higher viscosity and lower cooling temperatures may cause overloading of the circu-
lation pump. If this is the case, the cooling medium circuit must be adapted accordingly. In such cases,
contact the manufacturer.
CHECKLISTE FOR CHO 29 TO CHO 149
Controller Type “B”, see 6.4 (CHO 29 to CHO 149)
1) Remove the front plate and the two side panels.
2) Connect the supply devices or the external tank. Make sure that the level of the contents is higher than the
pump to support the automatic priming system. Use a T-fitting if necessary for filling (refer to Fig. 1, Point
5.2.1). One essential requirement is the availability of a suitable vent opening for the system, particularly for
chillers with gear pumps.
3) Open the filler screw on the pump head.
4) Tighten the screw again when only oil flows out.
5) Open the shut-off valve.
6) Open the switch cabinet with the key supplied (Fastened to the main switch when the chiller is delivered).
7) Ensure that the motor protection switches (“MTC” and “MTP”) are in position “0”.
8) Move the motor protection switches of the chiller to position “1”.
9) Make sure that the oil is able to circulate adequately. It the circuit might be interrupted by something such as
a valve, electrical valve, a filter or anything else, a by-pass circuit (automatic overflow valve) must be in-
stalled in order to prevent damage to the pump.
10) Lock the switch cabinet with the key.
11) Move the main switch of the chiller to position “1” (the temperature of the cooling medium is displayed).
Never touch any part of the refrigeration circuit when the chiller is running!
12) Start up the compressor by pressing the button for 3 seconds.
13) Wait until the chiller has attained the operating conditions. This is indicated when the display shows the preset
working range.
14) Because the pump starts up immediately, make sure that the direction of rotation for the pump matches the
direction of the arrow on the casing. If it is rotating in the opposite direction, turn off the main switch of the
chiller immediately and arrange for the polarity of the chiller to be reversed.
15) After a few minutes carefully open the filler screw again in order to remove any residual air. Tighten the screw
again afterwards.
16) Check whether the pressure shown is within the limits specified for the pump. If not, take appropriate action
to ensure that pump is able to run within the specified limits.
17) Wait for the compressor to switch on. The compressor symbol will appear on the display (see Section 6.4).
18) Check the inside of the chiller and the piping system for leakage or loose connections.
19) Fit the front panel and the two side panels back onto the casing.
20) The chiller is normally factory-set to the temperature required by the customer.
21) When the chiller is within the operating conditions set by the manufacturer, check whether the current uptake
of the chiller matches the data indicated on the identification plate and those contained in the table in the
supplement.
6. CHECK LIST FOR COMMISSIONING GLYCOL RECIRCULATING CHILLERS
After turning off the main switch for more than 1 hour or after extraordinary maintenance work, each
chiller start should be regarded as an initial start-up.
The initial start-up calls for a number additional checks to ensure safe and reliable performance of the
system.
REQUIREMENTS FOR THE WATER-GLYCOL MIXTURE
Quality:
A water-glycol mixture should be used for filling the chiller (glycol = ethylene glycol). Corrosion-inhibiting
additives may also be included provided they are explicitly authorized for this purpose by the manufac-
turer concerned. The glycol content must be at least 20% and should not exceed 25%.
Cold water discharge temperature Ethylene glycol in %

710.1760.00.04-03A 28/11/2012
20
± 0°C
- 5°C
- 10°C
20
20
25
General operating conditions:
The glycol recirculating chiller is designed for cooling medium temperatures of -10°C to ±0°C.
Conditions during commissioning:
Should liquid temperatures different to those described in the general operating conditions occur during
the initial start-up, be sure to contact the manufacturer.
CHECKLIST FOR CHG 08 TO CHG 65
Controller Type “A”, see 6.4 (CHG 08)
1) Remove the upper lid panel and the two side panels.
2) Open the tank cap and fill the tank (using a T-fitting if necessary) while watching the level indicator (refer to
Fig. 1, Point 5.2.1).
3) Open the filler screw on the pump head.
4) Tighten the screw again when only cooling medium flows out.
5) Open the shut-off valve.
6) Move the main switch of the chiller to position “1” (the display will show “OFF”, and the pump will start to
run).
7) Top up the tank again if too much cooling medium has flowed out of the shut-off valve. Fasten the tank cap
again afterwards.
8) After a few minutes carefully open the filler screw again in order to remove any residual air. Tighten the screw
again afterwards.
9) Replace the upper lid panel and the two side panels.
10) Start up the compressor by pressing the button for 3 seconds.
11) Wait until the chiller has attained the operating conditions. This is indicated when the actual temperature
shown in the display matches the preset target temperature.
12) When the chiller is within the operating conditions set by the manufacturer, check whether the current uptake
of the chiller matches the data indicated on the identification plate and those contained in the table in the
supplement.
Controller Type “B”, see 6.4 (CHG 24 to CHG 140)
1) Remove the front plate and the two side panels.
2) Open the tank cap and fill the tank (using a T-fitting if necessary) while watching the level indicator (refer to
Fig. 1, Point 5.2.1).
3) Open the filler screw on the pump head.
4) Tighten the screw again when only water-glycol mixture flows out.
5) Open the shut-off valve.
6) Open the switch cabinet with the key supplied (Fastened to the main switch when the chiller is delivered).
7) Ensure that the motor protection switches (“MTC” and “MTP”) are in position “0”.
8) Fill the tank to the maximum (upper arrow, level indicator is located on the bottom right of the frame). See
Section 6.1.1 (Water requirements).
9) Move the motor protection switches “MTC” and “MTP” to position “1”.
10) Make sure that the water-glycol mixture is able to circulate adequately. It the circuit might be interrupted by
something such as a valve, electrical valve, a filter or anything else, a by-pass circuit (automatic overflow
valve) must be installed in order to prevent damage to the pump.
11) Lock the switch cabinet with the key.
12) Move the main switch of the chiller to position “1” (the temperature of the cooling medium is displayed).
Never touch any part of the cooling circuit when the chiller is running!
13) Start up the compressor by pressing the button for 3 seconds.
14) Make sure that the direction of rotation for the pump matches the direction of the arrow on the casing be-
cause the pump starts up immediately. If it is rotating in the opposite direction, turn off the main switch of
the chiller immediately and arrange for the polarity to be reversed.
15) After a few minutes carefully open the filler screw again in order to remove any residual air. Tighten the screw
again afterwards.
16) Wait until the chiller has attained the operating conditions. This is indicated when the actual temperature
shown in the display matches the preset target temperature.
17) Check whether the pressure shown is within the limits specified for the pump. If not, take appropriate action
to ensure that pump is able to run within the specified limits.
18) Check the level in the tank and top it up if required. Put the tank cap back in place.
19) Wait for the compressor to switch on. The compressor symbol will appear on the display.
20) Check the inside of the chiller and the piping system for leakage or loose connections.
21) Fit the front panel and the two side panels back into place.
22) The chiller is normally factory-set to the temperature required by the customer.
23) When the chiller is within the operating conditions set by the manufacturer, check whether the current uptake
of the chiller matches the data indicated on the identification plate and those contained in the table in the
supplement.