Pfannenberg EB 210 Series Manual

Operating and Maintenance
Instructions
Chiller
Series EB 210 - EB 440
Version 1.0, June 2019

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Preface
The skills and information provided in the ORIGINAL OPERATING MANUAL are required for assembly and safe
operation of Pfannenberg chillers.
The information is presented in a brief, clearly arranged format. The chapters are numbered throughout.
Various unit types may be documented in this operating manual.
Pfannenberg chillers are subject to continuous improvement. Please understand that we must reserve the right to
changes in design, equipment and technology. For this reason, no claims to specific features of the unit can be
derived from the content of this operating manual.

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Content
1. General.................................................................................................................................................................5
1.1. Scope .........................................................................................................................................................5
1.2. The chiller...................................................................................................................................................5
1.3. Proper/Improper operation.........................................................................................................................5
1.4. Symbols in use...........................................................................................................................................6
2. Safety ...................................................................................................................................................................7
2.1. Safety instructions for the operator and personnel ....................................................................................8
2.2. Safety instructions for auxiliary and operating materials............................................................................9
2.2.1. Glycol .....................................................................................................................................................9
2.3. Residual risk.............................................................................................................................................10
3. Description of the chiller..................................................................................................................................11
3.1. Design Concept........................................................................................................................................11
3.2. Functional Diagram ..................................................................................................................................11
3.3. The Chiller: Overview...............................................................................................................................12
3.3.1. Refrigeration circuit –main components..............................................................................................12
3.3.2. Hydraulic circuit –main components ...................................................................................................12
3.3.3. Safety and protection devices..............................................................................................................13
3.3.4. Main switch...........................................................................................................................................13
3.3.5. Control unit / Display............................................................................................................................13
3.3.6. Connections .........................................................................................................................................13
3.4. Electrical and mechanical components....................................................................................................14
4. Technical data...................................................................................................................................................15
4.1. Application limits.......................................................................................................................................15
4.1.1. Ambient temperature limitation ............................................................................................................15
4.1.2. Voltage limitations................................................................................................................................15
4.2. Type label.................................................................................................................................................15
4.3. Technical data sheet (short form) ............................................................................................................16
4.4. Cooling performance curve......................................................................................................................18
4.4.1. EB 210 to 440.......................................................................................................................................18
4.4.2. Correction factors.................................................................................................................................18
4.4.3. Chiller envelope ...................................................................................................................................19
4.5. Pump performance curve.........................................................................................................................20
4.5.1. EB 210..................................................................................................................................................20
4.5.2. EB 260..................................................................................................................................................20
4.5.3. EB 310..................................................................................................................................................21
4.5.4. EB 360..................................................................................................................................................21
4.5.5. EB 410..................................................................................................................................................22
4.5.6. EB 440..................................................................................................................................................22
4.6. P&ID diagram...........................................................................................................................................23
4.6.1. Diagram................................................................................................................................................23
4.6.2. Key.......................................................................................................................................................23
4.7. Dimensional drawing................................................................................................................................24

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4.7.1. EB 210 to 260 - Dimensions ................................................................................................................24
4.7.2. EB 310 to 440 - Dimensions ................................................................................................................25
4.7.3. EB 210 to 260 –Connection................................................................................................................26
4.7.4. EB 310 to 440 –Connection................................................................................................................26
4.8. Minimum distance from obstacles or other objects..................................................................................27
5. Installation.........................................................................................................................................................28
5.1. Transport..................................................................................................................................................28
5.2. Unpack the chiller.....................................................................................................................................28
5.3. Set up the chiller.......................................................................................................................................31
5.4. Connect the chiller to the hydraulic pipes ................................................................................................31
5.5. Fill the tank and the hydraulic circuit........................................................................................................32
5.5.1. Process Water / Fluids.........................................................................................................................32
5.5.2. Corrosion protection.............................................................................................................................33
5.6. Connecting the chiller to the power supply ..............................................................................................34
6. Commissioning.................................................................................................................................................35
6.1. Preparation before switching on the chiller..............................................................................................39
6.2. Switch on chiller .......................................................................................................................................40
6.3. Stop and switch off chiller.........................................................................................................................40
7. Operating...........................................................................................................................................................41
7.1. Carry out settings .....................................................................................................................................41
7.2. Starting the chiller after an interruption ....................................................................................................41
7.3. Stop chiller and switch it OFF ..................................................................................................................41
8. Troubleshooting................................................................................................................................................42
9. Maintenance......................................................................................................................................................45
9.1. Maintenance instructions for your safety..................................................................................................45
10. Decommissioning, disposal ............................................................................................................................47
10.1. Decommissioning and storage.................................................................................................................47
10.2. Final decommissioning or disposal ..........................................................................................................47
11. Warranty ............................................................................................................................................................48
12. Appendix............................................................................................................................................................48
12.1. Step by step instruction............................................................................................................................48
13. Contact...............................................................................................................................................................49

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1. General
1.1. Scope
This documentation contains all the relevant information necessary for the installation, connection, commissioning
and maintenance of the chiller.
Prior to any work on the chiller, careful reading and observance of this documentation is mandatory.
NOTICE
Hereby, the manufacturer declares that any form of liability will be refused if it can be attributed to improper use,
unauthorized modifications or disregard of the instructions given in this manual.
The warranty expires as soon as one of the above conditions applies.
The customer / operator is obliged to provide this manual and all related documents to those responsible for
installation, operation, maintenance and repair.
1.2. The chiller
The chiller is a cooling unit that extracts heat from a liquid by means of a vapor compression refrigeration cycle.
The cooled liquid is referred to as a coolant and is used for heat removal of liquid-cooled components.
The heat absorbed by the customer application of the components is discharged to the environment on the warm
side of the refrigeration cycle.
The chillers described in this manual are intended to cool water or mixtures of water and glycol, generally used as
coolant in machines or production processes.
1.3. Proper/Improper operation
The specified application and storage limits must not be exceeded or fallen below.
Information on this can be found on the rating plate and in the Technical data.
Improper operation
Installation / operation:
•on moving units
•in areas with high heat radiation
•in areas with strong magnetic fields
•in areas with open flames
•in potentially explosive atmospheres
•near flammable products
•in areas with a salty atmosphere
•in areas with an aggressive atmosphere
•in excessively dusty areas

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1.4. Symbols in use
Safety instructions and markings
DANGER
Identifies an exceptionally hazardous situation. Severe, irreversible injuries or death will occur if this notice is
not observed
DANGER
Identifies an exceptionally hazardous situation in connection with electrical voltage. Severe, irreversible injuries
or death will occur if this notice is not observed
WARNING
Identifies an exceptionally hazardous situation. Severe, irreversible or deadly injuries could occur if this notice is
not observed.
CAUTION
Identifies a hazardous situation. Minor or moderate injuries could occur if this notice is not observed.
NOTICE
Notice is used to address practices not related to physical injury.
Before explanations
*Legend notice
 Placed before results of actions

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2. Safety
The chiller instructions must be read by the installer and personnel in charge for operation, before starting the
chiller.
All safety and security instructions given in this manual must be observed!
Only qualified personnel are allowed to install, operate and do the maintenance work.
Non-observance of the instructions may cause injuries and will cancel the manufacturer’s liability for subsequent
damage.
National regulations on accident prevention, regulations of the local power supply authorities as well as any specific
safety instructions for chiller must be observed.
The safety of the unit is only guaranteed, if it is used as intended.
The following points must be observed before commissioning and while operating the chiller:
•Familiarize yourself with all operating controls.
•Make sure that all working limits indicated within unit label are observed.
•Use protective devices to check electrical insulation. Do not carry out any work on any part of the equipment that
are live with wet clothing, hands and feet.
•Never spill or pour any cooling medium into the environment as this may cause health hazard.
•The components of the chiller must not be modified in any way.
•Disconnect the power supply and release pressure from any pressurized component before carrying out any
service work on the Chiller.
•A qualified commissioning engineer must ensure that the chiller has been connected to the electrical mains in
accordance with the standard EN 60204 and all other applicable national regulations.
It is also mandatory to comply with Regulation (EU) No 517/2014 of the European Parliament and of the Council of
16 April 2014 on certain fluorinated greenhouse gases.
The above mentioned Regulation lays down specific measures and restrictions to be considered while
commissioning, operating, maintaining and disposing any equipment containing greenhouse gases, such as HFCs,
as specified in Annex I. It also specifies mandatory leakage-check frequency to be performed by certified personnel
and mandatory records providing the evidence of exact fluorinated gas charge and subsequent added and/or
recovered quantities (e.g. Article 3).
CAUTION
Compliance with legal requirements
In accordance to the F-GAS regulation (EU) No 517/2014, every year the operator (the owner of the equipment)
is responsible to ensure a gas leakage test, the recording of the gas quantity change inside the unit and the
communication to the responsible agency of the state in the European community where the unit is in
operation.
If you need any consultancy in terms of a maintenance and leakage check according (EU) No. 517/2014 please
contact our Pfannenberg Service Team (see chapter Contact).
WARNING
Spare parts from third-party manufacturers can damage the unit
➢Only original parts are subject to the manufacturer's quality control.
➢Only use specially agreed harmonized manufacturer parts for safe and reliable operation.
For Pfannenberg spare part numbers, see supplied document Spare part list (part of the delivery)
If you have questions about spare parts, please contact our Pfannenberg Service Team (see chapter Contact).

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2.1. Safety instructions for the operator and personnel
For Health and Safety reasons, please find below a list of potential risks that the operator is exposed to while
commissioning and/or operating and/or dismantling the unit:
CAUTION
Sharp edges
Heat exchanger fins and internal metal plates live edges have sharp edges.
Avoid contact or wear safety equipment such as gloves and protective clothes.
CAUTION
Hot surface
To avoid possible skin burns, do not touch parts such as electric motor body of pump or
compressor and refrigeration copper pipes.
Wear safety equipment such as gloves and protective clothes.
CAUTION
Pressurized device
Refrigerant under pressure within refrigeration circuit (PS indicated on chiller data label).
Always verify functionality of High Pressure Switch.
Release pressure before maintaining or servicing the refrigeration circuit.
Due to toxicity of refrigerant and oil still inside circuit, it is recommended to use suitable gloves
and mask while servicing refrigerant equipment.
CAUTION
Pressurized device
Cooling water/glycol mixture under pressure within hydraulic circuits (max pressure indicated on
chiller data label).
Release pressure (use purge system and refill ball valve) before sectioning, maintaining or
servicing the hydraulic equipment.
Due to toxicity of refrigerant and oil still inside circuit, it is recommended to use suitable gloves
and mask while servicing refrigerant equipment.
DANGER
Electrical shock hazard
Always unplug or disconnect power supply before opening the unit.
Post a ‘MAINTENANCE WORK IN PROGRESS’ sign on a visible position next to the main
switch during service.
WARNING
Rotating fan blades
Can cause serious injury or cut.
Keep hands clear.
Always disconnect power supply and make sure all mechanical equipment is stopped before
service.

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DANGER
Toxic hazard
Toxicity of refrigerant and cooling liquid.
Avoid contact, inhalation or swallowing.
It is recommended to use suitable protection equipment (such as gloves, glasses, mask)
NOTICE
For environmental reasons never discharge refrigerant into atmosphere (follow local regulations to properly
dispose of refrigerant). It is recommended to familiarize with all technical documentation provided with the unit
(such as Controller manual, Hydraulic & Electric diagrams) to avoid improper operation of this unit.
2.2. Safety instructions for auxiliary and operating materials
2.2.1.Glycol
Get familiar with the MSDS of the glycol in use and follow all relevant safety instruction.

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2.3. Residual risk
There are some residual risks after the installation of the unit that must be considered:
Residual risks according to 2006/42/CE Directive:
•The condenser has fins on his external surface, so there is the possibility for the operator to touch sharp edges
during service of the unit.
•Although the unit is designed with all the possible safety requirements, in case of external fire there is the
possibility that the internal pressure and temperature of the unit will increase in a dangerous and uncontrollable
way; in that case use the extinguishing tools suitable for that conditions.
•Safety valve should be maintained according to the maintenance instruction (see chapter Maintenance) to avoid
malfunctions in case of necessity (e.g. in case of external fire the pressure of the refrigerant circuit could rise to a
critical value).
•For units without emergency switch-disconnector: chiller user must install the emergency switch-disconnector
installation close to the chiller, in an accessible and clearly visible place, to allow emergency stop of the unit and
safety for the operator.
•Even if the instructions contained in this manual are enough explanatory for safety, high pressure switches are
mounted, to guarantee intervention in case of wrong filing, or in case of malfunction due to not controlled
increase of pressure and temperature.
•Even if in this manual is clearly indicated to switch off the unit before doing any maintenance or control
operation, protection elements of the unit, as fixed panels, are not provided with safety devices that block the
operation of the unit if they are not mounted, in that case the operator could be exposed to contact with internal
rotating parts.
•In case of damage of fans protection grids, possible risk for the rotating part should be considered by the utilizer;
in this situation the unit should be immediately switched off and repaired.
Residual risks according to 2014/68/UE Directive:
•Although the unit is designed with all the possible safety requirements, in case of external fire there is the
possibility that the internal pressure and temperature of the unit will increase in a dangerous and uncontrollable
way; in that case use the extinguishing tools suitable for that conditions.
•For the series production of the standard units of category , the pressure resistance test (typically the
hydrostatic pressure test) is made on a statistic base, not on all units.
This can be accepted, also considering all the safety devices mounted on the units.
•For units without emergency switch-disconnector: chiller user must install the emergency switch-disconnector
installation close to the chiller, in an accessible and clearly visible place, to allow emergency stop of the unit and
safety for the operator.
•Even if the instructions contained in this manual are enough explanatory for safety, high pressure
switches/safety valves are mounted, to guarantee intervention in case of wrong filing, or in case of malfunction
due to not controlled increase of pressure and temperature.

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3. Description of the chiller
Pfannenberg chillers are intended to cool down liquid for industrial applications. The frigorific circuit removes the
heat from the water and rejects the condensing power to the ambient through the air ventilation circuit. The unit is
complete of a hydraulic circuit with pump and atmospheric tank to pump the cold water to the user’s device and
back to the cooling circuit.
3.1. Design Concept
The chiller is a cooling unit that extracts heat from a liquid by means of a vapor compression refrigeration cycle.
3.2. Functional Diagram
Main components:
1 Compressor
2 Air cooled condenser with fan
3 Expansion valve
4 Evaporator
5 Pump
6 Tank
Refrigerant circuit
•The compressor (1) compresses the refrigerant under high pressure. The temperature increases.
•This heat is released to the ambient air in the condenser (2). The refrigerant liquefies.
•The condenser fan draws ambient air through the condenser (2) and releases it to the environment.
•A pressure drop occurs when the refrigerant passes through the expansion valve (3).
•Inside the evaporator (4), the refrigerant absorbs heat from the coolant and evaporates.
Hydraulic circuit
•The pump (5) supplies chilled coolant to liquid cooled components on the customer application.
•The coolant absorbs heat and runs back into the chiller.
•While passing the evaporator, the coolant dissipates heat to the refrigerant.
•The chilled coolant runs back into the tank where the hydraulic circulation starts again.

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3.3. The Chiller: Overview
3.3.1.Refrigeration circuit –main components
Compressor
The choice of the compressor used depends on the cooling capacity of the chiller. Depending on the capacity,
reciprocating, rotary or scroll compressors are used. Each compressor is equipped with a thermal overload
protection.
Condenser
As a heat exchanger so-called Microchannel condenser are used, which consist of aluminum tubes and aluminum
fins.
NOTICE
The chiller is not intended to be installed or operated in an aggressive atmosphere, as this may damage the
condenser.
Fan
The fan is mounted on the top of the chiller and blows warm air upwards into the environment. A protective grid
prevents direct contact with any rotating parts.
Expansion valve
The valve is responsible for the optimum refrigerant charge of the evaporator and is factory set for each unit.
A change in the setting is only to be carried out by appropriate specialist personnel.
Evaporator
The evaporator used is a plate heat exchanger. This ensures the heat exchange between the coolant and the
refrigerant and consists of copper-brazed stainless steel plates.
3.3.2.Hydraulic circuit –main components
Pump
As standard, peripheral pumps are used which have different delivery rates depending on the device performance.
The flow rate is always assigned to a specific pressure which is directly dependent on the design of the pump used
and thus on the characteristic curve.
The information on the pump output always considers the internal pressure losses of the chiller.
In addition to the standard pump, more powerful pumps are available for higher pressure losses.
Tank
All chillers are equipped with a plastic tank. This serves as a buffer for the cool brine to always provide enough
liquid ready and reduces the number of ON-OFF cycles of the compressor.
The tank size is matched to the device performance.

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3.3.3.Safety and protection devices
Refrigerant circuit
High pressure switch
To avoid excessive pressure of the refrigeration system, the high-pressure switch switches off the compressor and
the condenser fan and triggers a common alarm message.
After checking the cooling circuit, it must be reset manually by pressing the appropriate button on the machine
display.
Antifreeze protection
The antifreeze protection device prevents the evaporator from freezing.
It verifies that the temperature of the coolant in the evaporator does not reach critical values and switches off the
refrigerant circuit when a preset minimum temperature value is reached. At the same time, a common alarm
message is triggered.
Refrigerant filter/dryer
To prevent a malfunction of the refrigerant circuit, a filter dryer is installed which binds dirt particles and moisture.
3.3.4.Main switch
The main switch (on the front panel) serves as a safety device to disconnect the chiller from the power supply.
3.3.5.Control unit / Display
The built-in controller takes over all relevant functions to ensure the operation of the chiller.
These include the function of the cooling circuit, the function of the hydraulic circuit and the transmission of error
messages.
Depending on the device configuration, the controller may differ in design and functionality.
A detailed description of the function and parameterization can be found in a separate document available online
using the machine's serial number or model.
3.3.6.Connections
Electric connection
The electrical panel is equipped with a cable gland for the input of the power cables and a multiple cable gland for
any other wiring, such as signals and alarms. Cable entry is provided on the side of the machine, in
correspondence with the front area where the electrical panel is located. Removing the side panel makes it easy to
route the cables inside the unit and then enter the electrical panel.
Hydraulic connection
The hydraulic connections are located on the back of the unit. These are not flat sealing and must therefore be
sealed during commissioning. The size depends on the chiller type.

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3.4. Electrical and mechanical components
Refrigeration and hydraulic circuits are accessible by removing the two lateral panels.
Compressor
Condenser
Dehydrator Filter
Sight glass
High pressure switch
Low pressure switch
Thermostatic Valve / Evaporator
Fan
Pump

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4. Technical data
4.1. Application limits
4.1.1.Ambient temperature limitation
Chiller is designed to operate in the ambient temperature range indicated on the type label. When ambient
temperatures are out of that range, manufacturer must be consulted.
4.1.2.Voltage limitations
According to CEI EN 60204-1, Pfannenberg standard chiller operation is guaranteed within these ranges:
•Nominal voltage ±10 % [V]
•Nominal frequency ±1 % [Hz]
Please refer to the type label to see the nominal operating conditions of the unit.
Nominal conditions
V min [V]
V max [V]
f min [Hz]
f max [Hz]
230 V / 1 ~ / 50 Hz
207
253
49.5
50.5
230 V / 1 ~ / 60 Hz
207
253
59.4
60.6
400 V / 3 ~ / 50 Hz
360
440
49.5
50.5
460 V / 3 ~ / 60 Hz
414
506
59.4
60.6
NOTICE
Special voltage
For units with special voltages please refer to the type label.
4.2. Type label
This is an example of a type label.
Important is the information of the chiller serial number, which is needed for all technical questions.

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4.3. Technical data sheet (short form)
EB 210 WT B
EB 260 WT B
Unit
Rated voltage
400 / 3 / 50
460 / 3 / 60
400 / 3 / 50
460 / 3 / 60
V / ~ / Hz
Cooling capacity (with pump) (1)
21.3 / 23.4
25.7 / 28.5
kW
Flow rate (pump)
54 / 64
70 / 84
l/min
Pump pressure
2.5
2.5
bar
Ambient temperature
+15 … +45
+15 … +43
°C
Target value tolerance
±2
±2
K
Refrigerant
R407C
R407C
Max power consumption
9.9 / 12.6
12.1 / 14.2
kW
Max current consumption
20 / 22
22 / 22.5
A
Starting current
72.8 / 80.5
89.9 / 89.7
A
Control voltage
24 AC
24 AC
V
Airflow external
7,000
7,000
m³/h
Tank volume
70
70
l
Connections (medium)
1 ¼”
1 ¼”
BSP
Sound pressure 1m @ 50 Hz (EN ISO
3741)
64
70
dB(A)
Weight (without packaging)
389
403
kg
E-box degree of protection EN 60529
IP54
IP54
Colour
RAL7035
RAL7035
EB 310 WT B
EB 360 WT B
Unit
Rated voltage
400 / 3 / 50
460 / 3 / 60
400 / 3 / 50
460 / 3 / 60
V / ~ / Hz
Cooling capacity (with pump) (1)
30.6 / 36.7
35.6 / 42.7
kW
Flow rate (pump)
82 / 98
90 / 107
l/min
Pump pressure
2.5
2.5
bar
Ambient temperature
+15 … +45
+15 … +45
°C
Target value tolerance
±2
±2
K
Refrigerant
R407C
R407C
Max power consumption
17.4 / 22.2
17.9 / 20.6
kW
Max current consumption
31 / 33
30 / 31
A
Starting current
126.7 / 132
122.6 / 125.7
A
Control voltage
24 AC
24 AC
V
Airflow external
12,000
12,000
m³/h
Tank volume
200
200
l
Connections (medium)
1 ½”
1 ½”
BSP
Sound pressure 1m @ 50 Hz (EN ISO
3741)
71
72
dB(A)
Weight (without packaging)
434
448
kg
E-box degree of protection EN 60529
IP54
IP54
Colour
RAL7035
RAL7035

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EB 410 WT B
EB 440 WT B
Unit
Rated voltage
400 / 3 / 50
460 / 3 / 60
400 / 3 / 50
460 / 3 / 60
V / ~ / Hz
Cooling capacity (with pump) (1)
40.5 / 48.5
43.5 / 52.2
kW
Flow rate (pump)
105 / 125
101 / 125
l/min
Pump pressure
2.5
2.5
bar
Ambient temperature
+15 … +43
+15 … +43
°C
Target value tolerance
±2
±2
K
Refrigerant
R407C
R407C
Max power consumption
18.1 / 21.8
19.1 / 23
kW
Max current consumption
31.5 / 33
34.5 / 35
A
Starting current
131.1 / 134.5
142.9 / 146.6
A
Control voltage
24 AC
24 AC
V
Airflow external
12,000
12,000
m³/h
Tank volume
200
200
l
Connections (medium)
1 ½”
1 ½”
BSP
Sound pressure 1m @ 50 Hz (EN ISO
3741)
72
74
dB(A)
Weight (without packaging)
476
500
kg
E-box degree of protection EN 60529
IP54
IP54
Colour
RAL7035
RAL7035

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4.4. Cooling performance curve
4.4.1.EB 210 to 440
4.4.2.Correction factors
Ambient air temperature [°C]
15
20
25
30
32
35
40
45
Cooling capacity
1.095
1.09
1.08
1.03
1
0.95
0.87
0.79
Ethylene glycol [%]
Propylene glycol [%]
20
30
50
20
30
50
Cooling capacity
0.99
0.98
0.96
0.99
0.98
0.96

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4.4.3.Chiller envelope

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4.5. Pump performance curve
4.5.1.EB 210
4.5.2.EB 260