omi CHA 1.3 Operating instructions

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Water / Water Heat exchanger
Výměník tepla voda / voda
CHA 1.3 to/až CHA 12
English
User and Maintenance Manual
Čeština
Manuál k provozu a údržbě
Save These Instructions
Tyto pokyny si uschovejte
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 ....................................................................... 3
1.1 HOW TO USE THIS MANUAL .................................................................................................... 3
1.2 GENERAL DESCRIPTIONS / INTENDED USE ............................................................................... 3
GENERAL SAFETY INSTRUCTIONS ........................................................................................ 3
3 DESCRIPTION OF THE UNIT, COMPONENTS AND OPTIONS .................................................. 4
3.1 DESCRIPTION ........................................................................................................................ 4
3.2 REFRIGERATION CIRCUIT (HOT SIDE) ...................................................................................... 4
3.2.1 STANDARD COMPONENTS USED IN THE WATER COOLER ........................................................................ 4
3.3 HYDRAULIC CIRCUIT (CONSUMER CIRCUIT) .............................................................................. 5
3.3.1 STANDARD COMPONENTS USED IN THE WATER COOLER ........................................................................ 5
3.3.2 OPTIONS – HYDRAULIC CIRCUIT .......................................................................................................... 5
3.4 ELECTRIC CIRCUIT ................................................................................................................. 5
3.4.1 STANDARD COMPONENTS USED IN THE WATER COOLER ........................................................................ 5
3.4.2 OPTIONS – ELECTRIC CIRCUIT ............................................................................................................ 6
3.5 HOUSING .............................................................................................................................. 6
4 TRANSPORT / PACKING / STORAGE ..................................................................................... 7
4.1 REMOVING THE WATER COOLER FROM PACKAGING AND HANDLING ............................................ 7
4.2 DISPOSAL OF PACKING MATERIALS ......................................................................................... 8
4.3 STORAGE .............................................................................................................................. 8
5 INSTALLATION AND ASSEMBLY ............................................................................................ 8
5.1 CHOOSING A LOCATION ......................................................................................................... 8
5.2 ASSEMBLY (CONNECTIONS) ....................................................................................................
5.2.1 CONNECTION TO THE REFRIGERANT CIRCUIT (CONSUMER CIRCUIT) ....................................................... 9
5.2.2 ELECTRIC CONNECTION ...................................................................................................................... 9
6 OPERATION ........................................................................................................................ 10
6.1 CHECK LIST FOR THE INITIAL START-UP OF WATER/WATER HEAT EXCHANGER SYSTEMS ............ 10
6.1.1 CHEC LIST MODELS CHA 1.3-11 ....................................................................................................... 10
6.1.2 CHEC LIST MODELS CHA 24-60 ........................................................................................................ 11
6.1.3 CHEC LIST MODELS CHA 99-129 ...................................................................................................... 11
6.2 OPERATING SETTINGS OF THE ELECTRONIC CONTROLLER ....................................................... 12
6.2.1 ELECTRONIC CONTROLLER ................................................................................................................ 12
6.3 SHUTTING DOWN THE WATER COOLER .................................................................................. 14
6.3.1 SWITCHING ON/OFF IN DAILY OPERATION .......................................................................................... 14
6.3.2 TEMPORARY DECOMMISSIONING ....................................................................................................... 14
6.3.3 DECOMMISSIONING FOR THE PURPOSE OF TRANSPORT ....................................................................... 14
7 MAINTENANCE ................................................................................................................... 14
7.1 MAINTENANCE ..................................................................................................................... 14
8 DISPOSAL ........................................................................................................................... 15
9 MALFUNCTIONS / TROUBLE SHOOTING ............................................................................. 15
.1 POSSIBLE ALARM SIGNALS AND THEIR RECTIFICATION ........................................................... 16
9.1.1 CONTROLLER TYPE “A”, “D”, (CHA 1.3 TO CHA 129) ............................................................................. 16
10 GENERAL TECHNICAL DATA / FUNKCE A TECHNICKÁ DATA ................................................ 34
10.1 TECHNICAL FEATURES / TECHNICKÉ FUNKCE ........................................................................ 34
10.2 HYDRAULIC CIRCUIT DATA / VLASTNOSTI ČERPADLA A NÁDRŽE ........................................... 34
10.3 COMPONENTS WITH A WEIGHT OF MORE THAN 20 KG
KOMPONENTY O HMOTNOSTI PŘESAHUJÍCÍ 20 KG ............................................................... 34
10.4 FLUIDS RECOMMENDATIONS / DOPORUČENÍ PRO KAPALINY ................................................ 35
11 DIAGRAMS / SCHÉMATA ..................................................................................................... 36
11.1 LEGEND / LEGENDA ......................................................................................................... 36
1 PED INFORMATION / PED INFORMACE .............................................................................. 38
13 INDIVIDUAL SPECIFICATION / INDIVIDUÁLNÍ SPECIFIKACE ........................................... 38

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1GENERAL USER AND MAINTENANCE MANUAL
1.1 HOW TO USE THIS MANUAL
This operating manual is intended for specialist staff involved in the installation, commissioning and
operation of CHA series. For the purposes of this operating manual, the general designation of “water
cooler” will be used for these devices.
This operating manual is an integral part of the water cooler. Every user, operator and service technician
must carefully read the information and instructions in this operating manual – especially those regarding
safety – before moving, installing, using, maintaining and disposing of the water cooler.
The owner of the water cooler must ensure that all works with and on the water cooler are only carried
out by properly trained personnel.
The installation and operating manual is divided into two sections that contains a detailed description of
the CHA series and additional information on the customer-specific design and model of your water
cooler, wherever these differ from the standard model. For example this is where you will find the
separate circuit diagram for this water cooler.
1. GENERAL DESCRIPTIONS / INTENDED USE
The water coolers have been developed in order to lower down economically with the lower energetic
consumption the liquid temperature, using the heat exchange between liquid and liquid.
The system’s overload determines a worsening of the water cooler performance (cooling capacity drop),
within the maximum usage limit, but does not compromise it’s safety.
A start and stop device (ON/OFF) allows the water cooler to be turned on and it permits its normal
functioning.
An electrical protection prevents the pump and other circuits parts damages.
The use of a water cooler is recommended for treatment of liquids in industrial, civil or commercial
cooling.
GENERAL SAFETY INSTRUCTIONS
SYMBOLS USED IN THE WATER COOLER/MANUAL
Water cooler
Liquid Inlet (Hot/Cold side)
WARNING DANGER
Read carefully the instructions,
break the power supply and
unload the parts under pressure
before any maintenance on the
unit.
Liquid Outlet (Hot/Cold side)
Fan Rotation Direction / Pump
Manual : Warning and danger symbols
GENERAL WARNING – GENERAL DANGER
General warning – general danger for the safety of people and objects
DANGER – ELECTRICAL POWER
Danger of electrocution during interventions on the parts of the water cooler and of the connected systems
/equipment with electrical power.
DANGER – HOT SURFACES/HIGH FLUID TEMPERATURE
Danger of burns due to the high temperatures of the hot parts of the water cooler and/or of the contained
fluids.
DANGER – MOVING PARTS
Danger of injury due to contact with the moving parts of the water cooler
DANGER – EYESIGHT DAMAGE
Danger of eyesight damage caused by the use of compressed air or liquid particles during cleaning
operations.
Any installation, use and maintenance operations must be done according to the instructions contained in the User and
Maintenance Manual and in accordance to the national rules. Any cleaning/maintenance operation which requires
access to the water cooler must be carried out by qualified and expert personnel who must be aware of all the
necessary precautions. Read the User and Maintenance Manual carefully before any operation. The water cooler has
been designed and manufactured to be used in conformity to the norms used in the country. In case of different use of
the water cooler or not in conformity to the User and Maintenance Manual, the Manufacturer can’t be considered
responsible.

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THE FOLLOWING POINTS MUST BE OBSERVED BEFORE COMMISSIONING AND WHILE OPERATING THE
WATER COOLER:
Familiarize yourself with all the operating controls.
The water cooler 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 water cooler are
functioning properly.
Never hit the pipes located on the inside of the water cooler 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 water cooler is resold, the cooling medium must be drained from the water
cooler using suitable equipment. Please contact customer service of the nearest dealer in this
connection.
 The side panels of the water cooler must not be removed unless this is absolutely necessary.
Even if the side panels are only partially removed, isolate the water cooler from the electricity
supply and affix a sign to the control panel bearing the warning “Maintenance work on water
cooler in progress”. Replace the side panels as quickly as possible.
The components of the water cooler must not be modified in any way.
Bypassing the electrical protective devices may result in overloading of the water cooler.
Possible risks
CAUTION: The water cooler is equipped with a main switch.
The authorized installation technician must ensure that the water cooler 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:
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 water cooler may
also be cooled with nebulised 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 effect.
In any case, it is necessary to reduce the ambient temperature and/or that of the water cooler 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.
Excessive pressure on the liquid side:
This equipment isn’t supplied with safety devices.
The safety devices must be carried out by the installer.
Such devices will have to be carried out according to the applicable National Norms and to the limits
mentioned in this manual.
3DESCRIPTION OF THE UNIT, COMPONENTS AND OPTIONS
3.1 DESCRIPTION
The water cooler is supplied ready for connection. It consists of an housing, a cooling medium circuit
(consumer medium circuit) and an electrical engineering, including all the control, regulation and
monitoring devices required for fully automatic operation. The cooling media selected and used shall
comply with the environmental protection standards and the legal provisions.
3. REFRIGERATION CIRCUIT (HOT SIDE)
3. .1 STANDARD COMPONENTS USED IN THE WATER COOLER
The preceding abbreviations indicate the position in the drawings.
Not all components are contained in all models.
SC – Heat exchanger
Finned pack and heat exchange fitted out of the tank or stainless steel plate heat exchanger.
EVS – Solenoid valve
These valves maintain the constancy of the fluid temperature by regulating the flow of cold water to the
heat exchanger.

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3.3 HYDRAULIC CIRCUIT (CONSUMER CIRCUIT)
3.3.1 STANDARD COMPONENTS USED IN THE WATER COOLER
MF – Pressure gauge for cooling medium
The pressure gauge indicates the pressure at the outlet for the cooling medium.
P – Pump
Single-stage or multi-stage centrifugal pump of horizontal or vertical design, depending on output.
3.3. OPTIONS – HYDRAULIC CIRCUIT
BP – Automatic bypass / Overflow valve
The overflow valve guarantees the minimum throughput in the cooling medium circuit. In the continuous
flow and single-circuit systems this protects the pump.
BPM – Manual bypass
Using this bypass the minimum throughput in the cooling medium circuit can be manually adjusted.
CAA – Automatic cooling medium feed by means of float valve
The cooling medium is filled up automatically by the float valve if the level in the tank falls below the
minimum.
EV 1 – Solenoid valve 1 (connect without current) in return circuit
These valves should be used in open systems and when consumers are positioned at a higher level.
Generally used as a valve combination with VNR.
FL – Differential pressure switch
The flow controller located in the cooling medium inlet monitors the flow in the cooling medium and
consumer cycles and switches off the cooling system if the flow falls short off the minimum.
LVE – Float switch (for single and dual circuit systems only)
The float switch is located in the tank and monitors the cooling medium level. This ensures the constancy
of the water outlet temperature and the dry-run protection of the pump(s).
If the water level drops further and the minimum limit value is reached, the cooling system and pump(s)
are switched off. The water cooler 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 system warms up the water in the tank. It can be used to achieve the correct operating
temperature in a short time if there is a low ambient temperature and no process heat.
TD – Digital thermometer in return circuit (systems with single and dual circuit)
The thermometer indicates the inlet temperature of the cooling medium.
VNR – Non-return valve in the supply line
These valves should be used in open systems and when consumers are positioned at a higher level.
Generally used as a valve combination with EV.
Dirt trap
If the cooling medium is expected to be contaminated by solids with a diameter > 1mm during operation,
a dirt trap with the appropriate mesh width has to be used. This should preferably be installed outside of
the equipment to allow an easy cleaning. It is important to note the flow direction. The dirt trap must be
cleaned at regular intervals after commissioning the water cooler.
Pump alternatives
A pump is provided as standard and supplies a pressure from 2 to 3 bar at a defined nominal flow rate.
Other pumps can of course be selected according to the project and then optimized to the desired flow
rate or pressure.
3.4 ELECTRIC CIRCUIT
3.4.1 STANDARD COMPONENTS USED IN THE WATER COOLER
IG – Main switch
When the main switch is turned off, the water cooler is current-free. The switch is located in the door of
the switch cabinet.
MTP – Motor protecting switch for pump
In the event of an increase in motor current or a short circuit, the motor protecting switch turns off and
interrupts the current supply. The motor protecting switch has to be turned on manually after the source
of the malfunction has been eliminated.
The motor protecting switch is located in the switch cabinet.

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ROO – Remote control
With the aid of an external contact, the water cooler can be switched off by the consumer or from a
control room. When this occurs, the main switch stays permanently in the "ON" position.
QE - Switch cabinet
The switch cabinet contains all the electrical components and the safety devices.
Connecting cable without plug.
Supplied ready for use with oilflex cable with 4 wires (3P/PEN) without plug.
TLT – Temperature controller
The temperature control and regulation is carried out by the temperature controller, which regulates the
temperature of the cooling medium according to the preset value. The temperature controller with digital
display is integrated in the door of the switch cabinet. Fault messages are displayed on the temperature
controller by means of codes.
3.4. OPTIONS – ELECTRIC CIRCUIT
Connecting cable with CEE plug
Supplied ready for use with oilflex cable and CEE plug 4 pole (3P+PEN) or 5-pole (3P+N+PE).
3.5 HOUSING
Legend :
01 Level
02 Power Supply
03 Control Panel
04I Water IN (hot side, application circuit)
04O Water OUT (hot side, application circuit)
05I Water IN (cold side, external cooling circuit)
05O Water OUT (cold side, external cooling circuit)
MODELS: CHA 1.3
MODELS A B H C D E F G I L M (Ø)
CHA 1.3 230 520 650 / / / / 35 / 25 / 12mm
MODELS: CHA 4, CHA 11
MODELS A B H C D E F G I L M (Ø)
CHA
4, 11
575
445
540
/
4 0
/
/
/
80
56
608
½”

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Legend :
01 Level
02 Power Supply
03 Control Panel
04I Water IN (hot side, application circuit)
04O Water OUT (hot side, application circuit)
05I Water IN (cold side, external cooling circuit)
05O Water OUT (cold side, external cooling circuit)
MODELS: CHA 24 to CHA 60
MODEL A B H C D E F G I L M (Ø)
CHA 24 580 650 / 845 41 80 583 80 / 82,5 61 1½”
CHA 40, 60 760 760 / 1250 767 100 72 100 / 84 1360 1½”
MODELS: CHA to CHA 12
MODEL A B H C D E F G I L M (Ø)
CHA 1325 760 / 1400 300 300 635 300 / 84 / 1½”
CHA 110 1325 760 / 1400 300 300 635 300 / 84 / 2“1/2“
CHA 12 1325 760 / 1400 300 300 635 300 / 84 / 2“1/2“
4TRANSPORT / PACKING / STORAGE
4.1 REMOVING THE WATER COOLER FROM PACKAGING AND HANDLING
Each water cooler is supplied in a reinforced carton on a wooden pallet. The water cooler must be kept in
an upright position at all times. NOTE: Tilting the water cooler may cause serious damage!
•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 water cooler using suitable lifting gear.
NOTE: If the water cooler is fitted with eyebolts, these must be used for lifting it in accordance
with the applicable safety standards.

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If the water cooler is not fitted with eyebolts, the lifting gear must be appropriate for the
weight of the water cooler, as indicated on the identification plate and in the Annex.
All the handling operations must be carried out by qualified personnel only.
•Remove the pallet (if present).
•Place the water cooler in the desired location.
•Remove the operating manual, accessories and key from the water cooler
4. DISPOSAL OF PACKING MATERIALS
We recommend that you keep the original packaging for the water cooler in case it has to be transported
to another location or sent to a service centre. In any case, the waste packaging material must be
deposited with the responsible waste disposal companies.
4.3 STORAGE
The water cooler must be stored in rooms protected from atmospheric agents, in dry ambient and at
temperatures between + 5 and + 50 °C.
In case of storage for more than 12 months, before starting up the water cooler again, contact
the Manufacturer to check the preservation condition of the components of the water cooler
especially of the electric ones.
5INSTALLATION AND ASSEMBLY
5.1 CHOOSING A LOCATION
Install the unit in a protected dry area, free of fumes, dust or inflammable vapors, with non-explosive
atmosphere and in any case free of any element that may affect its correct functioning.
A suitable area to ensure a constant temperature in all seasons no lower than + 2°C and in any case no higher than +
40°C, even when the water cooler is operating. To use the water cooler at room temperatures lower than + 2°C or
higher than + 40°C, contact the manufacturer for all necessary variations.
We suggest an adequate ventilation not to change the ambient temperature, since the water cooler tends to heat up
the room.
Horizontal installation surfaces, flat and adequate to support the load of the water cooler. Bigger water coolers are
fitted with holes to be fixed on the floor at the tip of the supporting feet.
For outdoor installation protect the water coolers from any direct contact with atmospheric agents.
Position the water cooler to allow an easy reading of the control instruments and an easy access to the controls.
Adequate space for the installation of system accessory components.
Guarantee adequate free space above the water cooler.
(Image for example. For the other versions see the letters. B is always the front panel)
Models A (m) B (m) C (m) D (m) E (m) INSTALLATION
CHA 1.3 0.5 0.5 0.5 1 0.5 Indoor
CHA 4, CHA 11 1 1 1 1 1
CHA 24, CHA 40, CHA 60 1 1 1 1 1 Outdoor with protections
CHA
,
CHA
110,
CHA
12
1
1
1
1
1
Outdoor (suggest with protections)

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5. ASSEMBLY (CONNECTIONS)
5. .1 CONNECTION TO THE REFRIGERANT CIRCUIT (CONSUMER CIRCUIT)
All operations must be carried out by qualified personnel only.
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 water cooler.
-Check the cleanliness of the supply line and the piping system to be connected.
-Connect the water cooler with the consumer circuit; the identification of the joints
(cooling medium inlet/outlet) is indicated on the water cooler by means of the symbols
described in the introduction to the manual.
-Make all the connections, without rotating the sleeves located on the hose.
The cooling medium circuits of the Series CHA 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
water cooler and the possible volume flow. This should not be smaller than the diameter of the water
cooler connections.
In the case of rigid connections, check during the initial start-up of the water cooler 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:
♦A bypass system with suitable valves upstream and downstream of the water cooler. This is
intended to allow use of the consumer circuit if you have to remove the water cooler from the
circuit, switch it off or use it in different ways at the same time.
♦A pipeline system with integrated filter near the water cooler to protect the pump against solid
matter and avoid deposits on the heat exchangers. The recommended mesh width for the water
coolers is 25µ with a maximum pressure loss at the filter of 1 bar.
♦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
intervention 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.
A Male-male fitting
B From the loading line
C To supply line
D “T” fittings
E Outlet water cooler fitting
5. . ELECTRIC CONNECTION
The features of the main (size, protection system, ground connection) must comply with the Legislation
in force in the destination country, in relation to the electric features of the water cooler.
Below are the main general installation prescriptions.
All operations must be carried out by qualified personnel only.
The mains supply should be established with a rubber sheathed line connected to a TN-C system with
direct earthing.
30 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 water cooler.
The protective earth conductor must be connected to the earthing point of the water cooler.
Fig.1

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400 V version (3 phase):
Connection with a three-phase, four-wire system (3/PEN AC). The three-phase conductor must be
connected directly to the main switch of the water cooler. No neutral conductor is used. The PEN must be
connected to the earthing point of the water cooler.
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
water cooler and agree with those in the table in the supplement and that the permitted values are not
exceeded. Check the mains for correct values and test the function of the earthing and protection
systems.
Install a general isolating switch for the electricity mains close to the water cooler. The connecting circuit
for the water cooler must be equipped with a circuit breaker and residual current protective device.
You can find information on the electrical power input values for the water cooler in the supplement.
Before you connect the water cooler to the mains, make sure that the general isolating switch
disconnects the water cooler 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 (CHA 4 to CHA 60) on
the base of the water cooler. Lay the cable on the upright up to the gland on the base of the switch
cabinet (CHA to CHA 12 ). 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!
6OPERATION
6.1 CHECK LIST FOR THE INITIAL START-UP OF WATER/WATER HEAT EXCHANGER
SYSTEMS
6.1.1 CHECK LIST MODELS CHA 1.3-11
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.
Controller Type “A”, “D”, see 6. (CHA 1.3 to CHA 11)
1) Remove the lid panel and the two side panels.
2) Fill up the collection tank. Remove or unscrew the cap of the collection tank and fill up keeping the level indicator
under control or use “T” fittings. (Refer to Fig.1 point 5.2.1).
3) Open venting screw on pump head.
4) Tighten screw again once only water flows out.
5) Open the outlet interception valve and after that the inlet one of the water cooler (if present).
6) Bring the main switch of the water cooler to position “1” (the display will show OFF and the pump running).
7) Top up the tank if necessary. Then replace the tank cover.
8) After a few minutes, open the filler screw again carefully to remove any remaining air. Retighten the screw.
) Replace the lid panel and the two side panels.
Holes for the passage of power cable
Position of flexible gland for the
power cable