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

9
OPERATING AND MAINTENANCE MANUAL
Chapter 4 - Description
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 4
D ESCRIPTION
4.1 Components
The data relating to the materials refer to standard machines. In case of particular units special materials are used, so it is necessary to refer to the
data on the offer.
The machines essentially consist of the following components:
• Refrigeration compressor
• Condenser
• Evaporator
•Tank
•Pump
• Frame/outer panelling
• Electronic controller
4.2 Cooling circuit
Models TAE K15÷K20 have a single refrigerant circuit with one compressor.
The circuits consist of the following components:
• refrigerant fluid used R134a;
• piston hermetic compressor;
• pressure switches for high and low refrigerant pressure;
• thermostatic throttle valve with external equalization (in models without prismatic tank);
• dryer filter;
• liquid flow sight glass;
• Schrader service valves;
Consult the enclosed drawings for additional information.
4.3 Compressors
All the machines are equipped with piston hermetic compressors, which are distinguished for their high energy efficiency, low vibrations and
consequent silence in normal operation.
They are cooled by the aspirated gas, protected against overheating of the windings by an internal module that monitors their temperature and,
upstream, by magnetothermic circuit breakers. These components are housed in a closed, but easily accessible, compartment.
4.4 Condenser
Condensation occurs through fin-pack coils consisting of copper tubes and collectors, aluminium fins and shoulders in galvanised sheet.
4.5 Evaporator
The evaporator is a finned pack type; the water flows in contact with the finned surface and at a speed that guarantees low pressure drops, while
the refrigerant fluid flows inside the tubes.
A plate exchanger can be fitted as an alternative.
In the TAE K15÷K20 models, the exchanger is protected against the formation of ice, caused by low evaporation temperatures, through an anti-
freeze function in the electronic controller. A probe monitors the temperature of the evaporator outlet water. If it is necessary to achieve a
negative ambient/water temperatures, a mixture of water and glycol must be used.
4.6 Tank
The storage tank is a prismatic atmospheric.
The tank can be protected against freezing by means of an electric heater managed by the electronic controller. A level sensor in the tank serves
to signal low water level conditions. The standard supply includes anti-condensation cladding, a drain valve and an air bleed valve. An internal
bypass between the water delivery and return connections, makes it possible to read the anti-freeze probe if the unit's process water inlet and
outlet connections are inadvertently closed. In this case the unit stops due to tripping of the antifreeze alarm and the shut-off valves must be
reopened.
The bypass serves exclusively to allow an antifreeze alarm to trip (if present) and to allow the pump to run with a reduced water flow rate
without damage. It is advisable to avoid repeated antifreeze alarm trip cycles in the foregoing conditions.
With the prismatic atmospheric tank process water
filling is performed utilising a kit comprising a semi-
transparent plastic container. In steady-state
operating conditions the liquid level must be about
half way up the container.

10
OPERATING AND MAINTENANCE MANUAL
Chapter 4 - Description
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.
4.7 Pump
Centrifugal pump is installed. It is possible that the machine is supplied without pump on board.
For more information consult the attached diagrams.
The pump seals are made of ceramics/treated carbon/EPDM.
ATTENTION
Bleed the circuit by unscrewing the bleed cap on the pump whenever the water circuit is filled .See 5.4 “Hydraulic connections” .
NOTE
The pump must never run dry.
4.8 Fans
Axial fans
The fans of axial type consist of a die-cast aluminium fan with sickle profile.
The protection rating of the fans is IP44 for TAE K15÷K20.
All fans have “F” insulation class to assure the external working with all types of climates. The assembly is completed with a superior (support
to the fan) safety protection grill.
4.9 Casing
The base, uprights and panels are made of galvanized carbon steel and held together by screws and/or rivets. All panels undergo a phosphor
degreasing process followed by epoxy polyester powder coating.
The frame is designed to allow easy access to all machine components.
4.10 Materials in contact with the liquid to be cooled
There can be two different groups.
Standard chillers: carbon steel, copper, aluminium, zinc, brass, stainless steel and plastics
in particular:
• evaporator with copper tubes, aluminium fins and shoulders in galvanised steel;
• tank in AISI 304 stainless steel;
• prismatic atmospheric tank
The pump mechanical seals are made of ceramics, graphite and/or EPDM.
4.11 Minimum distances from walls in the installation ambient
See enclosures.
4.12 Electrical circuit
For the electrical connections, see Chapter 5 “Installation“, Installation, and consult the enclosed drawings.
Model width depth height
TAE K15÷K20 (mm)
(in) 743 725 964

11
OPERATING AND MAINTENANCE MANUAL
Chapter 5 - Installation
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 5
I NSTALLATION
ATTENTION
Before carrying out the installation or operating on this machine, ensure that all the personnel has read and understood the Chapter 2
“Safety“ in this manual.
5.1 Inspection
Immediately after uncrating, inspect the unit.
5.2 Positioning
1. The unit may be installed both outdoors and indoors.
2. If installed indoors, the room must be well ventilated and with a sufficient height which allows the air to be expelled by fans. In
some cases it may be necessary to install fans or extractors to limit the temperature of the room.
3. The minimum and maximum working ambient temperature are specified on the unit data plate. In extreme temperature conditions,
the protection devices may trip.
4. The machine must be positioned on any flat surface capable of supporting its weight.
5. Leave at least one metre around the unit to permit access during service operations.
6. Do not obstruct or disturb the condenser's flow of thermal exchanging air.
5.3 Antifreeze protection
Even if the minimum working ambient temperature is above 0°C it is possible for the machine - during stoppages in the cold seasons - to find
itself in an environment with a temperature below 0°C.
In these cases, if the machine is not emptied, antifreeze (ethylene glycol) must be added in the following percentages to prevent the formation of
ice:
Add the following anti-freeze (ethylene glycol) percentages in order to avoid freezing when operating at low water outlet temperature:
5.4 Hydraulic connections
NOTE
All hydraulic connections must be carried out by the customer.
1. Connect the unit to the water piping respecting the water flow direction as indicated in the annexed overall dimension drawings.
2. Provide two cocks (one at the inlet and one at the outlet) for excluding the unit when maintaining without emptying the user water
circuit.
3. Fill the water receptacle by unscrewing the plug and filling the circuit with water (for example using a hose connected to the tap)
until the level in the receptacle is about half-way up the slot.
The receptacle used for filling the circuit acts as an open expansion tank. It is therefore necessary to pay attention to the volumes and dimensions
in play.
Ambient temperature up to
[°C] (°F) Ethylene Glycol [% in weight]
0 (32) 0
-5 (23) 15
-10 (14) 25
-15 (5) 30
Table 4 A
DDING ETHYLENE GLYCOL BASED ON THE AMBIENT TEMPERATURE
Water outlet temperature up to
[°C] (°F) Ethylene Glycol [% in weight]
5 (41) 0
0 (32) 15
-5 (23) 20
-10 (14) 30
Table 5 A
DDITION OF E THYLENE GLYCOL ACCORDING TO THE WATER OUTLET TEMPERATURE

12
OPERATING AND MAINTENANCE MANUAL
Chapter 5 - Installation
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.
NOTE
The pump must never run dry.
ATTENTION
If the unit is furnished without hydraulic group, it is necessary to install a pump for the evaporation water circuit.
For maintenance purposes, we recommend installing a water drainage cock in the lower part of the circuit.
Evaporator water connection size
ATTENTION
For correct operation, we strongly recommend the installation of a water filter to be connected to the inlet pipe to avoid the entry of solid
particles that could damage the pumps. The non-observance of this instruction can cause big damages to the evaporator.
TAE
unit model 015÷020
Evaporator water IN/ OUT
connections
Rp 3/4”
Process water inlet Process water outlet
When filling the circuit with liquid check to ensure the absence of air bubbles and
contaminants. If the pump runs noisily or emits anomalous noise it may be necessary to
bleed the liquid circuit in order to prime the pump.
The procedure is as follows:
• unscrew the filler/breather plug at the top of the pump
• fill the hydraulic circuit until water starts to overflow from the filled hole
• refit the plug and tighten it
Repeat the operation if the pump continues to run noisily, in such a way as to eliminate
any air that had previously remained trapped in the impeller vanes.
PLUG

13
OPERATING AND MAINTENANCE MANUAL
Chapter 5 - Installation
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.
5.5 Electrical connections
The connection of the unit to the power supply network must be done in conformity with the laws and prescriptions in force in the installation
place.
The power supply voltage, the frequency and the phase number must be as shown on the unit data plate.
The power supply voltage must not be, also for short periods, out of the tolerances given in the wiring diagram.
Except for different indications, the frequency tolerance is +/-1% of the nominal value (+/-2% for short periods).
In the event of three-phase supply, the system must be symmetrical (equal effective voltage values and equal phase angles among consecutive
phases).
In particular, except for different indication, the max. unbalance between each phase is 2%. The unbalance is calculated as following:
Vavg= average of voltage phases
In the event of single-phase supply, check that there is a neutral line in the electrical installation and it is earthen in the transformer cabin (TN
system in compliance with IEC 364) or that this is done by the electricity supply company (TT system in compliance with IEC 364).
The phase conductor and the neutral wire must not be confused.
For the electrical supply:
1. connect the unit (PE terminal in the electrical panel) to the earthed system of the building
2. guarantee the automatic interruption of the power supply in the event of insulation failure (protection against indirect contacts in
compliance with IEC 364) by means of a differential device (normally with operation nominal current of 0.03 A)
3. at the beginning of the electrical supply cable must be guaranteed a protection against direct contacts with a protection degree of
IP2X or IPXXB at least
4. at the beginning of the electrical supply cable must be installed protection devices that protect against overcurrents (short circuit)
(see information in the electrical wiring)
5. use conductors which transform the max. current required to the max. operating ambient temperature, according to the selected
installation type (IEC 364-5-523) (see information in the electrical wiring)
6. protection devices must be installed to limit the short circuit current to peaks of 17 kA corresponding to the specified interruption
power if the short circuit current envisaged at the point of installation is greater than an effective value of 10 kA.
Indications of electrical wiring:
A max. size permitted for the fuse type gG.
In general, the fuses can be replaced with an automatic switch regulated by means of the unit max. absorbed current (contact the
manufacturer if necessary)
B section and type of the power supply cable (if not already supplied):
• installation: insulated conductors, multipolar cable in duct, in air or over masonry (C type in compliance with IEC 364-5-523
1983) or without no other cable in contract
• working temperature: the max. working ambient temperature of the unit
• cable type: copper conductors, PVC insulation from 70°C (if not specified) or EPR insulation from 90°C
Consult the enclosed electrical diagram for additional information.
Max difference of each phase from Vavg
Vavg x100

14
OPERATING AND MAINTENANCE MANUAL
Chapter 6 - Start up
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 6
S TART UP
ATTENTION
Before starting up these units be sure that all personnel have read and understood the Chapter 2 “Safety”.
1. Check that the machine's on/off valves are open.
2. Check that the tank is completely full of water and properly vented.
3. Check that the ambient temperature is within the limits indicated in the machine data plate.
4. It is possible to check that the pressure is about 0.5 bar on the manometer located on the back of the unit (only if the water circuit is
of the closed type).
5.Check that the main switch is in the OFF position (“0”).
6.Check that the power supply voltage is correct.
7.Power the machine by means of the supply line protection device.
8.Turn the machine main switch ON (“I”).
9.Check that the water flows across the evaporator.
10. Press
" button for 5 seconds if you want to start the unit.
The led
# flashes for 5 seconds and then it remains lit.
To power-off the machine, press the
" key.
11. In three-phase units, check that compressor works correctly (it must not be noisy or overheated) and check that the fans and the
pump (if installed) rotation direction is correct.
If necessary invert two phases of supply.
12. Check that the pressure difference between the value read on the manometer located on the machine control panel with the pump in
motion and the value read with the pump stopped is higher than the available pressure with the pump's maximum flow capacity. If
this difference is lower, it means that the water flow capacity is higher than the maximum value allowed. In order not to damage the
pump, it is necessary to increase the pressure drop of the hydraulic circuit by, for example, partially closing a pump discharge cock.
13. If with the first start-up, there is a high ambient temperature and the temperature of the water in the hydraulic circuit is much higher
than the working value (e.g. 25-30°C) this means that the chiller starts up overloaded with the consequence of possible tripping of
the protection devices. To reduce this overload, a chiller outlet valve can be gradually (but not totally!) closed to reduce the flow of
water passing through it. Open the valve as the water temperature in the hydraulic circuit reaches the working value.
14. The machine is now ready for operating.
If the thermal load is lower than that produced by the unit, the water temperature drops until it reaches the set point (ST01
parameter) set following the instruction of chapter Electronic Board.
When SET-POINT value has been reached, the electronic control controlling the water inlet temperature stops the compressor. The
water pump, on the other hand, is always in motion.

15
OPERATING AND MAINTENANCE MANUAL
Chapter 7 - Electronic Board
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 7
E LECTRONIC B OARD
7.1 Display
The display is divided in 3 zones.
7.1.1 Display icons
7.2 Function of buttons
Top-left zone
It displays the temperature of temperature regulation probe.
NOTE
The displaying depends on the setting of parameter CF36 (see chapter
7.9 “ Values displayed” ).
Bottom-left zone
It displays the operating setpoint, OFF with stand-by unit.
NOTE
The displaying depends on the setting of parameter CF42 (see chapter
7.9 “ Values displayed” ).
Right zone
Signalling icons.
ICON MEANING ICON MEANING
$
Celsius degrees (If displayed)
%
Low pressure alarm
Fahrenheit degrees (If not displayed)
&
Antifreeze resistance
'
Bar/Psi
(
Pump on
)
Compressor 1
*
Flow meter alarm
+
Compressor 2
,
Time to defrost starting
-
Stand-by unit
.
Fans on
/
General alarm
0
Indication for Function Menu entering
1
High pressure alarm
BUTTON FUNCTION
2
It selects water temperature and ambient air temperatures in the top part of the display.
During programming phase it scrolls the parameter’s codes or increases their values.
3
If pressed for 5 seconds, it allows to switch on or off the unit in chiller modality.
It selects water temperature in the top part of the display. During programming phase it
scrolls the parameter’s codes or decreases their values.
4
If pressed for 5 seconds, it allows to display or modify the set point.
During programming phase it selects a parameter of confirms a value.
!
It allows to enter Function Menu.

16
OPERATING AND MAINTENANCE MANUAL
Chapter 7 - Electronic Board
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.
7.2.1 Function of combined buttons
7.3 Symbols and leds on the display
7.4 Remote terminal
7.4.1 Function of buttons
If there is no communication between the unit and the remote terminal, in the top part of the
display it appears the message “
!"# ” (no link).
NOTE
The displaying depends on the setting of parameter CF43-CF44 (see chapter 7.9 “ Values displayed” ).
7.5 Displaying during an alarm
BUTTONS FUNCTION
35 + 54
To enter programming phase (pressed for 5 sec).
25 + 54
To exit programming phase.
25 + 54
If pressed for more than 5 seconds they allow to start a manual defrosting cycle (function not present).
LED LED STATUS MEANING LED LED STATUS MEANING
6
Not enabled
7
Not enabled
#
Steady Unit on in chiller modality
7
Not enabled
7
Flashing Programming phase (if flashes
together with
# led)
,
Clock adjustment
7
Not enabled
BUTTON FUNCTION
8
It allows to enter Function Menu.
9
If pressed for 5 sec., it allows to display or modify the set point.
During programming phase it selects a parameter or confirms a value.
:
It selects water temperature in the top part of the display.
During programming phase it scrolls the parameter’s codes or increases their
values.
;
It selects water temperature in the top part of the display.
During programming phase it scrolls the parameter’s codes or decreases their
values.
<
If pressed for 5 seconds it allows to switch on or off the unit.
=
Not enabled
During normal operation (no alarm), when an alarm occurs the alarm
code and the appropriate icon flash in the bottom part of the display,
alternated to the temperature / pressure.

17
OPERATING AND MAINTENANCE MANUAL
Chapter 7 - Electronic Board
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.
7.5.1 Alarm icons
There are four icons for alarm signalling:
7.6 How to silence the buzzer
Automatic silencing: it happens when the cause of the alarm has been eliminated.
Manual silencing: press and release one of the four buttons; the buzzer silences even if the alarm condition persists.
7.7 First start up
At the first start up of the unit in the bottom part of the display it could appear the message “ $%& ” alternated with the temperature. It indicates
that it is necessary to regulate the clock.
If the probes used to control the unit are not connected or are damaged, the appropriate alarm will be displayed.
However, it is possible to regulate the clock or to programme the unit.
7.8 Programming by keyboard
The parameters of electronic control are divided in two groups and in two levels:
1. USER (Pr1);
2. SERVICE (Pr2).
USER level allows to access user parameters, SERVICE level allows to access the parameters of unit configuration (it is protected by a
password).
The parameter’s groups, indicated by some “Label”, are divided as follows:
7.8.1 Access to “Pr1” parameters (User level)
To enter the menu of “Pr1” parameters which can be access by the user:
1. Press for some seconds
4 + " buttons ( 7 and # start flashing), in the top of the display appears “ALL”, the first group of
parameters.
2. Select the various groups using
> and " buttons.
3. After selecting a group, press
4 button: if the selected group is part of the selected menu or any parameter of this group has been
moved in this menu, in the bottom of the display it appears the “Label” and the code of the group’s first parameter present in “Pr1”,
its value appears in the top of the display.
It will not be possible to enter a parameter’s group which is not part of this menu.
4. It is possible to scroll or modify the parameters contained in the group.
7.8.2 How to modify a parameter’s value
1. Enter the programming procedure.
2. Select the desired parameter.
3. Press
4 button to enable the value’s adjustment.
4. Modify the value by means of
> and " buttons.
5. Press
4 to store the new value and to pass to the code of the following parameter.
6. To exit the procedure: Press
4 + > when a parameter is displayed, or wait (about 240 seconds) without pressing any button.
/
General alarm
1
High pressure alarm
%
Low pressure alarm
*
Flow meter alarm
LABEL ACTION
ALL It displays all parameters
ST It displays Thermoregulation parameters
CF It displays Configuration parameters
Sd It displays only the parameters of the Dynamic Setpoint (NOT ENABLED FUNCTION)
ES It displays only the parameters of the Energy Saving (NOT ENABLED FUNCTION)
CO It displays Compressor parameters
FA It displays Fan parameters
Ar It displays only the parameters of the Antifreeze Resistance
dF It displays only the parameters of the Defrosting (NOT ENABLED FUNCTION)
AL It displays only the Alarm parameters
LS It displays only the LASER parameters (NOT ENABLED FUNCTION)

18
OPERATING AND MAINTENANCE MANUAL
Chapter 7 - Electronic Board
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.
NOTE
The new value is stored also when the programming procedure is terminated for “time out”, without pressing 4 button.
ATTENTION
You can modify the parameter of the CF (configuration parameters) family only when the unit is in stand by.
7.9 Values displayed
The values visualized on the display change according to the configuration of parameters CF36 for the top part and CF42 for the bottom part.
For remote terminal it changes according to the configuration of parameters CF43 for the top part and CF44 for the bottom part.
Parameter CF36/CF43 = 0
In the top part of the display it appears the probe BEWOT
Parameter CF36/CF43 = 1
In the top part of the display it appears the probe BTWOT
Parameter CF36/CF43 = 2
No value will appear in the top part of the display
Parameter CF36/CF43 = 3
In the top part of the display it appears the probe BAT1
Parameter CF36/CF43 = 4
In the top part of the display it appears the chiller set; off when unit in stand-by
Parameter CF36/CF43 = 5
In the top part of the display it appears “OnC” when the unit is operating; off when unit in stand-by
Parameter CF36/CF43 = 6
In the top part of the display it appears the LASER set (FUNCTION NOT ENABLED)
Parameter CF36/CF43 = 7
No value will appear in the top part of the display
Parameter CF36/CF43 = 8
In the top part of the display it appears the operating differential
Parameter CF42/CF44 = 0
In the bottom part of the display it appears the probe BEWOT
Parameter CF42/CF44 = 1
In the bottom part of the display it appears the probe BTWOT
Parameter CF42/CF44 = 2
In the bottom part of the display it appears the probe PCP1
Parameter CF42/CF44 = 3
In the bottom part of the display it appears the probe BAT1
Parameter CF42/CF44 = 4
In the bottom part of the display it appears the chiller set; off when unit in stand-by
Parameter CF42/CF44 = 5
In the bottom part of the display it appears “OnC” when the unit is operating
Parameter CF42/CF44 = 6
In the bottom part of the display it appears the LASER set (FUNCTION NOT ENABLED)
Parameter CF42/CF44 = 7
No value will appear in the bottom part of the display
Parameter CF42/CF44 = 8
In the bottom part of the display it appears the operating differential
If the probe BTWOT has been selected has default, every time you press
> for 30 sec the top display visualizes the BEWOT probe, in the
bottom part of the display it will appear the “Label” Pb2 than the default value will return to be displayed.
If the probe BEWOT has been selected has default, every time you press
> for 30 sec the top display visualizes the BTWOT probe, in the
bottom part of the display it will appear the “Label” Pb1 than the default value will return to be displayed.
7.10 Unit switching on / off
The pressure of " button for 5 seconds allows to switch on or off the unit.
The led of icon
# flashes for 5 seconds then it remains lit.
7.11 How to put the unit in stand-by
Stand-by modality is obtained every time the unit is switched off.
It is indicated by the symbol
- lit.
Also in stand-by modality the controller can:
1. Display the measured values
2. Manage the alarms by displaying and signalling.