Rehsler Kuhlsysteme TAE K15 Operating instructions

38171300180_010
TAE K15÷K20
W ATER C HILLERS
OPERATING AND MAINTENANCE MANUAL
W ASSERKÜHLER
BEDIENUNGS- UND WARTUNGSANLEITUNG

1
OPERATING AND MAINTENANCE MANUAL
- Contents
TAE K15÷K20
The data in this manual are not binding and may be changed by the manufacturer without notice. Reproduction of this manual, even partial, is strictly prohibited.
C ONTENTS
C ONTENTS .......................................................................................................................................................1
G ENERAL I NFORMATION ................................................................................................................................3
1.1 How to interpret the model...................................................................................................... 3
S AFETY .............................................................................................................................................................4
2.1 General .................................................................................................................................... 4
2.2 Liquids of the user circuit........................................................................................................ 4
2.3 Lifting and carriage precautions.............................................................................................. 4
2.4 Installation precautions............................................................................................................ 5
2.5 Precautions during operation................................................................................................... 5
2.6 Maintenance and repair precautions........................................................................................ 5
2.7 Refrigerant gases ..................................................................................................................... 6
2.7.1 Refrigerant safety schedule .......................................................................................................................6
T ECHNICAL DATA ............................................................................................................................................8
3.1 Other data relative to the standard machines........................................................................... 8
3.1.1 Dimensions ................................................................................................................................................8
3.1.2 Characteristics of pumps ...........................................................................................................................8
D ESCRIPTION ...................................................................................................................................................9
4.1 Components............................................................................................................................. 9
4.2 Cooling circuit......................................................................................................................... 9
4.3 Compressors ............................................................................................................................ 9
4.4 Condenser................................................................................................................................ 9
4.5 Evaporator ............................................................................................................................... 9
4.6 Tank......................................................................................................................................... 9
4.7 Pump........................................................................................................................................ 10
4.8 Fans.......................................................................................................................................... 10
4.9 Casing...................................................................................................................................... 10
4.10 Materials in contact with the liquid to be cooled .................................................................... 10
4.11 Minimum distances from walls in the installation ambient..................................................... 10
4.12 Electrical circuit....................................................................................................................... 10
I NSTALLATION ...............................................................................................................................................11
5.1 Inspection ................................................................................................................................ 11
5.2 Positioning............................................................................................................................... 11
5.3 Antifreeze protection............................................................................................................... 11
5.4 Hydraulic connections............................................................................................................. 11
5.5 Electrical connections.............................................................................................................. 13
S TART UP .......................................................................................................................................................14
E LECTRONIC B OARD ....................................................................................................................................15
7.1 Display..................................................................................................................................... 15
7.1.1 Display icons ...........................................................................................................................................15
7.2 Function of buttons.................................................................................................................. 15
7.2.1 Function of combined buttons .................................................................................................................16
7.3 Symbols and leds on the display ............................................................................................. 16
7.4 Remote terminal ...................................................................................................................... 16
7.4.1 Function of buttons .................................................................................................................................. 16
7.5 Displaying during an alarm ..................................................................................................... 16
7.5.1 Alarm icons ..............................................................................................................................................17
7.6 How to silence the buzzer........................................................................................................ 17
7.7 First start up............................................................................................................................. 17

2
OPERATING AND MAINTENANCE MANUAL
- Contents
TAE K15÷K20
The data in this manual are not binding and may be changed by the manufacturer without notice. Reproduction of this manual, even partial, is strictly prohibited.
7.8 Programming by keyboard.......................................................................................................17
7.8.1 Access to “Pr1” parameters (User level) ................................................................................................17
7.8.2 How to modify a parameter’s value .........................................................................................................17
7.9 Values displayed ......................................................................................................................18
7.10 Unit switching on / off .............................................................................................................18
7.11 How to put the unit in stand-by................................................................................................18
7.12 Function menu ( ! button) ......................................................................................................19
7.12.1 Access to Function menu ..........................................................................................................................19
7.12.2 Exit Function menu ..................................................................................................................................19
7.12.3 How to display the alarms “ALrM” .........................................................................................................19
7.12.4 How to reset an alarm “rSt” ....................................................................................................................19
7.12.5 How to display the alarm historic “ALoG” .............................................................................................19
7.12.6 How to reset the alarm history “ArSt” ....................................................................................................19
7.12.7 Displaying the operating hours of loads “C1Hr - C2Hr - PFHr” ..........................................................20
7.13 Other functions by keyboard....................................................................................................20
7.13.1 How to display the Set Point ....................................................................................................................20
7.13.2 How to modify the Set Point .....................................................................................................................20
7.14 Probe key..................................................................................................................................20
O THER COMPONENTS SETTING ....................................................................................................................21
8.1 Compressor integral protection (PI).........................................................................................21
8.2 Refrigerant high and low pressure switches.............................................................................21
8.3 Compressor operation ..............................................................................................................21
8.3.1 Compressor regulation graphic in Chiller mode .....................................................................................21
O PERATION AND MAINTENANCE ..................................................................................................................22
9.1 Operation..................................................................................................................................22
9.2 Maintenance .............................................................................................................................22
9.3 Unit access................................................................................................................................22
9.4 Maintenance schedule ..............................................................................................................23
T ROUBLE SHOOTING .....................................................................................................................................24
S ETTING TABLES ...........................................................................................................................................27
11.1 Parameter setting......................................................................................................................27
11.1.1 Thermoregulation parameters .................................................................................................................27
11.1.2 Configuration parameters ........................................................................................................................27
11.1.3 Dymanic set point parameters (NBCP1OT ENABLED FUNCTION) .....................................................28
11.1.4 Energy Saving parameters (NOT ENABLED FUNCTION) ....................................................................28
11.1.5 Compressor parameters ...........................................................................................................................28
11.1.6 Fan parameters ........................................................................................................................................28
11.1.7 Antifreeze support resistance parameters ................................................................................................28
11.1.8 Defrost parameters (NOT ENABLED FUNCTION) ................................................................................28
11.1.9 Alarm parameters .....................................................................................................................................28
11.1.10LASER parameters (NOT ENABLED FUNCTION) ................................................................................28
ALARMS ..........................................................................................................................................................29
12.1 Alarm codes and actions ..........................................................................................................29
12.2 Outlet blocking.........................................................................................................................32

3
OPERATING AND MAINTENANCE MANUAL
Chapter 1 - General Information
TAE K15÷K20
The data in this manual are not binding and may be changed by the manufacturer without notice. Reproduction of this manual, even partial, is strictly prohibited.
C HAPTER 1
G ENERAL I NFORMATION
The machines described in this manual are called “WATER CHILLERS”.
This manual is written for those responsible for the installation, use and maintenance of the unit.
The components used are of high quality and all the projecting process, from the production to the unit checking, has been manufactured in
conformity with ISO 9001 norms.
In most applications, the liquid of the user circuit is water and the term “WATER” will be used even if the liquid of the user circuit is different
from water (e.g. a mixture of water and glycol).
Here below the term “PRESSURE” will be used to indicate the gauge pressure.
The following symbols are shown on the stickers on the unit as well as on the overall dimension drawing and refrigeration circuits in this manual.
Their meaning is the following:
1.1 How to interpret the model
TAE K15: Refrigerator with tank (Tank), air-cooled condenser, three-phase power supply and 1,5 hp (indicative power) hermetic compressor.
TAE K20: Refrigerator with tank (Tank), air-cooled condenser, three-phase power supply and 2.0 hp (indicative power) hermetic compressor.
ATTENTION
This manual provides the user, installer and maintenance technician with all the technical information required for installation, operation
and carrying out routine maintenance operations to ensure long life.
If spare parts are required, this must be original.
Requests for SPARE PARTS and for any INFORMATION concerning the unit must be sent to the distributor or to the nearest service centre,
providing the MODEL and MACHINE NUMBER shown on the machine data plate and on the first page of this manual.
Process water inlet
Process water outlet
Indications for lifting the unit
Water drainage point from the machine
Electric shock risk
Risk of burns from contact with high-temperature surfaces
Direction of the refrigerant fluid and water circuit
Direction of pump rotation (if installed)
Water filling point
Air vent
Cooling air flow (for air-condensed units)
Table 1 S
YMBOLS

4
OPERATING AND MAINTENANCE MANUAL
Chapter 2 - Safety
TAE K15÷K20
The data in this manual are not binding and may be changed by the manufacturer without notice. Reproduction of this manual, even partial, is strictly prohibited.
C HAPTER 2
S AFETY
This machinery was designed to be safe in the use for which it was planned provided that it is installed, started up and maintained in accordance
with the instructions contained in this manual. The manual must therefore be studied by all those who want to install, use or maintain the unit.
The machine contains electrical components which operate at the line voltage, and also moving parts.
It must therefore be isolated from the electricity supply network before being opened. Maintenance operations involving work inside the machine
must be performed by skilled and adequately qualified personnel equipped with suitable protection means (active and passive, e.g. work gloves)
ton ensure work in maximum safety. Do not allow extraneous persons (such as children) where the machine is installed.
2.1 General
When handling or maintaining the unit and all auxiliary equipment, the personnel must operate with care observing all instructions concerning
health and safety at installation site.
ATTENTION
Most accidents which occur during the operation and maintenance of the machinery are a result of failure to observe basic safety rules or
precautions.
An accident can often be avoided by recognising a situation that is potentially hazardous.
The user should make sure that all personnel concerned with operation and maintenance of the unit and all auxiliary equipment have read and
understood all warnings, cautions, prohibitions and notes written in this manual as well as on the unit.
Improper operation or maintenance of the unit and auxiliary equipment could be dangerous and result in an accident causing injury or death.
We cannot anticipate every possible circumstance which might represent a potential hazard.
The warnings in this manual are therefore not all-inclusive.
If the user employs an operating procedure, an item of equipment or a method of working which is not specifically recommended, he must ensure
that the unit and auxiliary equipment will not be damaged or made unsafe and that there is no risk to persons or property.
Any improper use of the machine will relieve the manufacturer from any liability for possible personal injury or property damage.
Arbitrary modifications made to the unit will automatically invalidate all forms of guarantee provided by the manufacturer.
ATTENTION
The hot / cold water produced by MTA units cannot be used directly for domestic hygiene or food applications. In the
case of such applications, the installer is responsible for fitting an intermediate exchanger.
If the intermediate exchanger is not fitted, the installer should affix a notice stating "non-drinking water".
2.2 Liquids of the user circuit
The liquids of the user circuit must be compatible with the materials used. These can be water or mixtures of water and glycol, for example.
Additives and glycol suppliers must guarantee compatibility with the materials. For further information refer to 4.10 “Materials in contact with
the liquid to be cooled” .
ATTENTION
If the liquids of the user circuit contains dangerous substances (e.g. ethylene glycol) is very important to collect any liquid which leaks
because it could cause damages to the ambient. Furthermore, when the chiller is no longer used, dangerous liquids must be disposed of by
firms specialised and authorised for treating them.
2.3 Lifting and carriage precautions
Avoid injury by using a hoist to lift heavy loads.
Check all chains, hooks, shackles and slings are in good condition and are of the correct capacity.
They must be tested and approved according to local safety regulations.
Cables, chains or ropes must never be applied directly to lifting eyes.
Always use an appropriate shackle or hook properly positioned.
Arrange lifting cables so that there are no sharp bends.
Use a spreader bar to avoid side loads on hooks, eyes and shackles.
When a load is on a hoist stay clear of the danger area beneath and around it.
Keep lifting acceleration and speed within safe limits and never leave a load hanging on a hoist for longer than is necessary. The weight values
shown in the following table were obtained with the unit empty, pump P3 and axial fans.
The manufacturer does not supply bars, belts and lifting hooks with the unit.
NOTE
Weight values are guideline, with the water circuit empty. The values may vary in relation to the configuration of the unit (pump type, supply
type, and ventilation type).

5
OPERATING AND MAINTENANCE MANUAL
Chapter 2 - Safety
TAE K15÷K20
The data in this manual are not binding and may be changed by the manufacturer without notice. Reproduction of this manual, even partial, is strictly prohibited.
2.4 Installation precautions
The connections to be made are for the process water circuit. Use the electrical diagram accompanying this manual to for the connection to the
power grid.
2.5 Precautions during operation
Operation must be carried out by competent personnel under a qualified supervisor.
All the water piping must be painted or clearly marked in accordance with local safety regulations in the place of installation.
ATTENTION
Never remove or tamper with the safety devices, guards or insulation materials fitted to the unit or auxiliary equipment.
All electrical connections must comply with local codes.
The unit and auxiliary equipment must be earthen and protected by fuses against short-circuits and overloading.
When mains power is switched on, lethal voltages are present in the electrical circuits and extreme caution must be exercised whenever it is
necessary to carry out any work on the electrical system.
Do not open any electrical panels or cabinets or touch any electrical components or associated equipment while voltage is applied unless it is
necessary for measurements, tests or adjustments. Such work should be carried out only by a qualified electrician equipped with the proper tools
and wearing appropriate body protection against electrical hazards.
2.6 Maintenance and repair precautions
ATTENTION
When disposing of parts and waste material of any kind make sure that there is no pollution of any drain or natural water-course and that no
burning of waste takes place which could cause pollution of the air. Protect the environment by using only approved methods of disposal.
Keep a written record of all maintenance and repair work carried out on the unit and auxiliary equipment. The frequency and the nature of the
work required over a period can reveal adverse operating conditions which should be corrected.
ATTENTION
Use only refrigerant gas specified on the specification plate of the unit.
Make sure that all instructions concerning operation and maintenance are strictly followed and that the complete unit, with all accessories and
safety devices, is kept in good working order. The accuracy of pressure and temperature gauges must be regularly checked. They must be
renewed when acceptable tolerances are exceeded.
ATTENTION
Do not weld or carry out any operation which produces heat near a system which contains oil or flammable liquids. The systems which may
contain oil or flammable liquids must be completely drained and cleaned (with steam, for example), before carrying out these operations.
The adjacent components must always be screened with non-flammable material and if the operation is to be carried out near any part of the
lubrication system, or close to a component which may contain oil, the system must first be thoroughly purged, preferably by steam cleaning.
Never use a light source with an open flame to inspect any part of the machine.
For every unit establish a suitable time schedule for cleaning operations.
ATTENTION
If replacement parts are needed use only original spares.
Avoid to damage the safety valves and other pressure relief devices.
All guards must be reinstated after carrying out repair or maintenance work.
ATTENTION
Check the direction of rotation of electric motors (the pump if installed) when starting up the unit initially and after any work on the
electrical connections or switch gear.
Do not use flammable liquid to clean any component during operation. If chlorinated hydrocarbon non-flammable fluids are used for cleaning,
safety precautions must be taken against any toxic vapors which may be released.
ATTENTION
Before removing any panels or dismantling any part of the unit, carry out the following operations:
- Isolate the unit from the main electrical power supply by disconnecting the cable from the electrical power source.
- Lock the isolator in the “OFF” position with a lock.
- Attach a warning label to the main isolator switch conveying: “WORK IN PROGRESS - DON NOT APPLY VOLTAGE”.
- Do not switch on electrical power or attempt to start the unit if a warning label is attached.
Coloured tracers can be used in service-maintenance operations.

6
OPERATING AND MAINTENANCE MANUAL
Chapter 2 - Safety
TAE K15÷K20
The data in this manual are not binding and may be changed by the manufacturer without notice. Reproduction of this manual, even partial, is strictly prohibited.
Inspect all refrigerant circuit joints including connectors, flanges, and more generally all critical points (open joints) in order to prevent possible
leakage of refrigerant gas.
2.7 Refrigerant gases
R134a is used as refrigerant in these units. Never attempt to mix refrigerant gases. The manufacturer's instructions and local safety regulations
should always be observed when handling and storing high pressure gas cylinders.
2.7.1 Refrigerant safety schedule
R134a
Denomination: R134a (1,1,1,2 - tetrafluoroethane)
INDICATION OF THE DANGERS
Major dangers: Asphyxia
Specific dangers: Unknown
FIRST AID MEASURES
General information: Do not give anything to unconscious persons
Inhalation: Take the person outdoors. Use oxygen or artificial respiration if necessary. Do not administer
adrenaline or similar substances
Contact with the eyes: Thoroughly wash with plenty of water for at least 15 minutes and call a doctor
Contact with the skin: Wash immediately with plenty of water.
Remove contaminated clothing immediately
FIRE-FIGHTING MEASURES
Means of extinction: Any means
Specific dangers: Pressure increase
Specific methods: Cool the containers with water sprays
MEASURES IN THE EVENT OF ACCIDENTAL LEAKAGE
Individual precautions: Evacuate personnel to safe areas. Provide adequate ventilation. Use means of personal protection
Environmental precautions: Evaporates
Cleaning methods: Evaporates
HANDLING AND STORAGE
Handling
technical measures/ precautions: Only use in well-aired premises
recommendations for safe use: tightness test. Do not carry out any pressure tests with air/R134a mixtures. It can form a
combustible mixture with the air at pressures above atmospheric pressure when the ratio in volume
exceeds 60%
Storage: Close properly and store in a cool, dry well-ventilated place
CONTROL OF EXPOSURE/INDIVIDUAL PROTECTION
Control parameters: 1000 ppm v/v or ml/m3 as weighted average over 8 hours
Respiratory protection: For rescue and maintenance work in tanks, use autonomous breathing apparatus. The vapours are
heavier than air and can cause suffocation, reducing the oxygen available for breathing
Protection of the eyes: Safety goggles
Protection of the hands: Rubber gloves
Hygiene measures: Do not smoke
PHYSICAL AND CHEMICAL PROPERTIES
Colour: Colourless
Odour: Similar to ether
Boiling point: -26.5°C / -15.7°F at atm. press.

7
OPERATING AND MAINTENANCE MANUAL
Chapter 2 - Safety
TAE K15÷K20
The data in this manual are not binding and may be changed by the manufacturer without notice. Reproduction of this manual, even partial, is strictly prohibited.
Flammability point: Non flammable
Relative density: 1.21 kg/l at 25°C
Solubility in water: 0,15% in weight (25°C at atm. press.)
STABILITY AND REACTIVITY
Stability: No reactivity if used with the relative instructions
Materials to avoid: Alkaline metal, earthy alkaline metals, granulated metals salts, Al, Zn, Be, etc. in powder.
Hazardous decomposition products: Halogen acids, traces of carbonyl halides
TOXICOLOGICAL INFORMATION
Acute toxicity: ALC/inhalation /4 hours/lab. rats = 567 ml/l
Local effects: Concentrations substantially above 1000 ppm v/v can cause narcotic effects. Inhalation of products
in decomposition can lead to respiratory difficulty (pulmonary oedema)
Long-term toxicity: Has not shown any cancerogenic, teratogenic or mutagenic effects in experiments on animals
ECOLOGICAL INFORMATION
Global warming potential HGWP
(R11=1): 0.28
Ozone depletion potential ODP
(R11=1): 0
Considerations on disposal: Usable with reconditioning
R134a

8
OPERATING AND MAINTENANCE MANUAL
Chapter 3 - Technical data
TAE K15÷K20
The data in this manual are not binding and may be changed by the manufacturer without notice. Reproduction of this manual, even partial, is strictly prohibited.
C HAPTER 3
T ECHNICAL DATA
The main technical data are given on the machine data plate:
ATTENTION
The performance of the unit mainly depends on the flow and temperature of the water in the user circuit and on the temperature of the
thermal exchanger fluid of the condenser. These data are defined during the offer stage.
3.1 Other data relative to the standard machines
3.1.1 Dimensions
See enclosures.
3.1.2 Characteristics of pumps
NOTE
The values in the table may vary in relation to the model and configuration of the unit. In this case reference should be made to the data in the
offer.
NOTE
The head is the head available to the user. It is possible for the pump installed to be different from the standard. There are two numbers for
the flow rate and pressure: the first number refers to the nominal conditions while the second to the maximum conditions.
MODEL and CODE
They identify the size of the unit and the type of construction.
MANUAL
This is the code number of the manual.
SERIAL NUMBER
This is the construction number of the unit.
MANUFACTURING YEAR
This is the year of the final test of the unit.
VOLTAGE/PHASE/FREQUENCY
Electric alimentation characteristics.
MAX. CONSUMPTION (I max)
This is electrical current consumed by the unit during the limit working conditions.
INSTALLED POWER (P max)
It is the power absorbed by the unit during the limit working conditions.
PROTECTION
As defined by the EN 60529 European standard .
REFRIGERANT
This is the refrigerant fluid in the unit.
REFRIGERANT QUANTITY
This is the quantity of refrigerant fluid contained in the unit.
MAX. COOLING PRESSURE
This is the design pressure of the refrigeration circuit.
MAX. COOLING TEMPERATURE
This is the design temperature of the refrigeration circuit.
USER CIRCUIT FLUID
Fluid used by the unit (normally water).
MAX. UTILIZATION PRESSURE
Max. designed pressure of the utilization circuit.
MAX. TEMPERATURE
Design temperature of the user circuit; this should not be confused with the maximum
working temperature which is established when the offer is made.
CONDENSER COOLING FLUID
Fluid the machine uses to cool the condenser.
MAX. WORKING PRESSURE
Maximum design pressure of the condenser cooling circuit.
MAX. TEMPERATURE
Maximum designed temperature of the cooling circuit of the condenser.
SOUND PRESSURE LEVEL
Sound pressure level in a free field in hemispherical irradiation conditions (open field)
at a distance of 1 m from the machine, condenser side, and at 1.6 m from the ground.
AMBIENT TEMPERATURE
Min. and max. cooling air temperature value.
WEIGHT
This is the approximate weight of the unit before packing.
Table 2 D
ATA PLATE AND MEANING OF ABBREVIATIONS
Model K15 K20
Tank capacity water volume (litres)
(galUS) 50 13 50 13
PUMP
water flow rate (m
3
/h)
(gpm)
1.2/4.8
5.3/21.1 1.2/4.8 5.3/21.1
pump head (bar)
(PSI) 5.2/2.4 75.4/34.8 5.2/2.4 75.4/34.8
nominal power (kW) 1.65 1.65
Table 3 C
HARACTERISTICS OF STANDARD UNITS