Riedel P030 User manual

Original
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OPERATING MANUAL
P030 Chiller
Glen Dimplex Deutschland GmbH
Geschäftsbereich RIEDEL Kältetechnik
Am Goldenen Feld 18
D-95326 Kulmbach
Phone: [phone] / 709 555
Fax: [phone] / 709 549
HEADQUARTERS GERMANY
Phone: [phone] / 709 545
Fax: [phone] / 709 529
e-mail: [e-mail]
http://www.Riedel-Cooling.com
PARTS & SERVICE
HOTLINE
NORTH AMERICA
Phone: ++1-877 RIEDEL1
Phone: ++1-877 -743 -3351
Fax: ++1-734 -595 -9829
e-mail: [e-mail]
http://www.riedel-usa.com

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This document was drawn up by the Technical Documentation Dept. of Glen Dimplex Deutschland GmbH.
Glen Dimplex reserves all rights to this documentation, especially the right to reproduce, distribute and translate this
document. This also applies with respect to application for patents and industrial rights. No part of this document
may be reproduced, processed, copied or distributed by either conventional or electronic means without the prior
written consent of Glen Dimplex. Subject to errors and technical changes.
Glen Dimplex assumes no responsibility for any errors in this documentation. To the extent permissibly by law, Glen
Dimplex will not be liable for any warranty claims for direct or indirect damages arising in connection with the supply
or non-use of this documentation.
Ordering information:
Documentation order number
To be entered by the user:
Inventory number:
Installation site:

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TABLE OF CONTENTS
1 FOR YOUR SAFETY..........................................................................................................5
1.1 R EGULATIONS ...................................................................................................................................................5
1.2 S IGNS AND S YMBOLS ........................................................................................................................................6
1.3 S AFETY N OTICES ..............................................................................................................................................7
1.4 H ANDLING OF R EFRIGERANTS ............................................................................................................................8
1.5 S AFETY R EQUIREMENTS ....................................................................................................................................9
1.6 P URPOSE OF THE P030 C HILLER .....................................................................................................................10
1.7 D ECLARATION OF C ONFORMITY .......................................................................................................................11
2 DESCRIPTION OF THE P030 CHILLER..........................................................................12
2.1 O VERVIEW P030 C HILLER ...............................................................................................................................12
2.2 R EFRIGERATION C IRCUIT .................................................................................................................................12
2.3 W ATER C IRCUIT ..............................................................................................................................................14
2.4 C OOLING A IR S UPPLY .....................................................................................................................................14
2.5 S AFETY D EVICES ............................................................................................................................................15
2.6 M ONITORING D EVICES .....................................................................................................................................15
2.7 E LECTRICAL /C ONTROL E QUIPMENT .................................................................................................................16
3 TECHNICAL DATA........................................................................................................... 17
3.1 H YDRAULIC D ATA ............................................................................................................................................17
3.2 E LECTRICAL D ATA ...........................................................................................................................................17
3.3 G ENERAL D ATA ...............................................................................................................................................17
3.4 N AME P LATE ...................................................................................................................................................18
4 TRANSPORT AND STORAGE......................................................................................... 19
4.1 T RANSPORT S PECIFICATION ............................................................................................................................19
4.2 T RANSPORT U SING A F ORKLIFT .......................................................................................................................20
4.3 T RANSPORT U SING A L IFT T RUCK ....................................................................................................................21
4.4 T RANSPORT U SING A C RANE ...........................................................................................................................22
4.5 S TORAGE OF THE P030 C HILLER .....................................................................................................................23
5 INSTALLATION................................................................................................................24
6 MOUNTING.......................................................................................................................25
6.1 C ONNECTION OF W ATER P IPING ......................................................................................................................25
6.2 E LECTRO -T ECHNICAL C ONNECTION .................................................................................................................26
6.3 O PTICAL F IBRE C ONNECTION ..........................................................................................................................26
7 COMMISSIONING ............................................................................................................28
7.1 W ATER C IRCUIT ..............................................................................................................................................28
7.2 I NITIAL S TART -U P OF THE P UMP ......................................................................................................................30
7.3 R EFRIGERATION C IRCUIT .................................................................................................................................30
8 DECOMMISSIONING .......................................................................................................31
9 SHUTDOWN IN EMERGENCIES.....................................................................................32
10 ENVIRONMENTAL REQUIREMENTS.............................................................................33
11 OPERATION OF CONTROL AND OPERATING UNIT....................................................34
11.1 C ONTROL AND O PERATING U NIT ST 181..........................................................................................................34
12 MAINTENANCE................................................................................................................36

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12.1 R EPLACING F ILTER E LEMENT ..........................................................................................................................37
13 PERIODICAL INSPECTIONS AND TESTS......................................................................38
14 MALFUNCTIONS / TROUBLESHOOTING ......................................................................40
14.1 M ALFUNCTIONS / T ROUBLESHOOTING OF C ONTROL AND O PERATING U NIT ST 181............................................40
15 OPTIONS..........................................................................................................................44
15.1 W ATER C IRCUIT ..............................................................................................................................................44
15.2 E LECTRICAL S YSTEM ......................................................................................................................................44
15.3 C OOLING A IR S UPPLY .....................................................................................................................................44

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1 FOR YOUR SAFETY
1.1 Regulations
Design, construction and development of the P030 Chiller are in compliance with the following
national and international regulations.
EC Directives / Standards
EC Machinery Directive 2006/42/EC
EC EMC Directive 2004/108/EC
EC Pressure Equipment Directive 97/23/EC
EN 378-1:2008 + A1:2010 Refrigerating systems and heat pumps. Safety and environmental
requirements – Part 1, Basic requirements, definitions,
classification and selection
EN 378-2:2008 + A1:2009 Refrigerating systems and heat pumps. Safety and environmental
requirements – Part 2, Design, construction, testing, marking and
documentation
EN 378-3:2008 Refrigerating systems and heat pumps. Safety and environmental
requirements – Part 3, Installation site and personal protection
EN 378-4:2008 Refrigerating systems and heat pumps. Safety and environmental
requirements – Part 4, Operation, maintenance, repair and
recovery
EN 60529:1991 + A1:2000 Degrees of protection provided by enclosures (IP)
EN 12100:2004, Parts 1 + 2 Safety of machinery – Basic concepts, general principles for design
EN 13857:2008 Safety of machinery – Safety distances to prevent hazard zones
being reached by upper and lower limbs
EN 349:1993 + A1:2008 Safety of machinery – Minimum gaps to avoid crushing of parts of
the human body
EN 60204-1: Electrical equipment of machines – Part 1: General
2006 + A1:2009 requirements
EN 61000-6-2:2005 Electromagnetic compatibility/generic immunity standard
EN 61000-6-4: Electromagnetic compatibility/generic emission standard
2007 + A1:2011
EN ISO 14121-1:2007 Safety of machinery. Risk assessment – Part 1
National Directives
BGR 500, Chapt. 2.35 Accident prevention regulations concerning refrigeration plants
and heat pumps

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1.2 Signs and Symbols
Throughout this operating manual, the information and notices below are identified by the following
graphical symbols:
Danger!
Safety note pointing out an imminent danger. Failure to heed the warning may result in serious
bodily injury and even death.
Caution!
Safety note to indicate the presence of a potential hazard. Failure to heed the safety notice may
result in minor bodily injury.
Notice!
This symbol identifies important information or a useful tip concerning the application of the
equipment.

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1.3 Safety Notices
For the installation, operation and maintenance of the P030 Chiller the following regulations and
safety notices have to be observed:
Danger!
•Any work on the P030 Chiller may only be performed by qualified personnel.
•All relevant accident prevention regulations have to be observed.
•Do not allow anybody to stand or pass underneath the forks when lifting and
setting down the P030 Chiller, stay clear of the danger area.
•The P030 Chiller must be properly secured in order to prevent it from tipping
over.
•The safety devices must not be deactivated.
•The electrotechnical connections of the P030 Chiller must be performed
according to and conforming to all relevant VDE, EN and. IEC standards. Beyond
that, the technical connection requirements of the local electrical utility company
have to be complied with.
•Always disconnect the power supply before working on the P030 Chiller.
Caution!
•Specific regional or national provisions applicable in the country where the unit
will be installed must be adhered to.
•The closed refrigeration circuit contains refrigerants and refrigeration oil. These
must be properly disposed of when performing service work or placing the unit
out of service (environment).
•The cooling water additives have a caustic effect on skin and eyes. When working
with cooling water additives, protective safety goggles and gloves must be worn.
Follow the directions on the product labels.
•Anyone working on the refrigeration circuit must be protected by personal
protective equipment.
•The P030 Chiller is to be used exclusively for the cooling of water and water-
glycol mixtures in accordance with predefined specifications.
Notice!
•Watch out for any incompatibilities of materials in the entire water circuit.
•The water must be free of all substances that could result in mineral deposits and
corrosion.

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The water used in the cooling circuit must comply, at a minimum, with the values specified by the
Ordinance on Drinking Water. In the case of de-ionised water, additional constructional features are
necessary.
Based on the drinking water ordinance the following limit values are recommended:
Drinking Water Properties
Appearance: clear, no sediments
Colour: transparent
Ingredients Unit Value
Electric conductivity at 25 °C: µS/cm 80 -750
Hydrogen concentration at 20 °C pH value 6.5 –9.5
Chloride (max.) mg/l 250
Total hardness (min.) °dH 6
Total colony count at 22°C (max.) CFU s/ml 100
1.4 Handling of Refrigerants
Notice!
•When handling refrigerants, all legal provisions and guidelines must be complied
with. Only qualified personnel may perform these activities.
The operator of the P030 Chiller is responsible for the proper disposal of used refrigerants and
system parts.

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1.5 Safety Requirements
Operation of P030 Chillers within the European Union:
The following information applies to P030 Chillers with closed refrigeration cycles that are used
within the European Union. In some member states additional requirements may apply, e.g. due to
environmental considerations.
The P030 Chillers contain components whose working pressures are subject to the regulations laid
down in the Pressure Equipment Directive 97/23/EC and European standard EN 378 (Parts 1 − 4,
most recent version).
Apart from the requirements relating to the design, equipment and testing of the P030 Chiller prior
to delivery to the customer, also the operator of such systems has to comply with requirements in
accordance with European standard EN 378 and possibly additional national regulations. These
concern the installation, the operation and periodical inspections/tests of P030 Chillers.
1.5.1 Installation
The P030 Chiller is designed for outdoor operation. The installation altitude must not exceed 2000m
above sea level. The height difference between the installation site of the P030 Chiller and the
COO system separator (Siemens Magnetic Resonance Tomograph) must not exceed −30 to +10
meters.
1.5.2 Operation
The owner or operator of the P030 Chiller has the obligation to establish emergency practices (in
the case of accidents and malfunctions). Based on this Operating Manual, the operator must draw
up a short version of the operating instructions (quick reference guide) and make it available to the
employees.
Notice!
•The quick reference guide must be clearly legible and affixed in the immediate
vicinity of the P030 Chiller.
(See Sample Quick Reference Guide)
•The owner or operator has the obligation to keep a logbook for the P030 Chiller.
he system logbook must either be available on site near the P030 Chiller, or in the event that the
data are stored in a computer of the owner or operator, a printout of the log must be kept in the
vicinity of the P030 Chiller. It must be ensured that these data are accessible to qualified persons
for the performance of repairs and periodical inspections/tests.
1.5.3 Periodical Inspections/Tests
To ensure compliance with minimum safety and health requirements as set forth in standard EN
378, regular tests and inspections of the P030 Chiller are to be carried out by competent persons.
Notice!
•The operator of the unit is responsible for the performance of periodical
inspections and tests.
(See Chapter Periodical Inspections/Tests).

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1.6 Purpose of the P030 Chiller
The P030 Chiller described in this manual is designed for outdoor use and is intended exclusively
for the cooling of water, or a water-glycol mixture (ratio 60: 40%), for the system separator (COO of
the P030 Chiller).
The system separator supplies the connected components (equipment to be cooled) with cooling
water maintaining its temperature at a constant level. It may only be operated in conjunction with
the specified devices.
Notice!
•No changes are allowed to be made to the P030 Chiller.
•The P030 Chiller must not be operated or used in conjunction with other than the
specified components and devices.

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1.7 Declaration of Conformity

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2 DESCRIPTION OF THE P030 CHILLER
The P030 Chiller is a unit ready for plug-in and is equipped with a refrigeration and water circuit
including all fittings and regulating/control devices required for automatic operation. The heat
extracted from the water is given off to the ambient air by means of the refrigeration circuit via the
condenser and the fans.
2.1 Overview P030 Chiller
View of an open chiller
1. Pressure vessel
2. Fan
3. Condenser
4. Expansion tank
5. Evaporator
6. Compressor
7. Control cabinet
8. Control switch
9. Main switch
10. Vent
11. Pump
2.2 Refrigeration Circuit
The refrigeration circuit is a closed-loop system in which the refrigerant R134 circulates as the heat
transfer medium.
The water heated by the system separator is recooled in the evaporator (4). The liquid refrigerant is
thereby passed through the piping in a counter-flow arrangement with respect to the water. The
refrigerant evaporates as it takes up the waste heat from the cooling water of the system separator.

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The vaporised refrigerant is drawn in by the three compressors (1) and is then compressed (rise in
pressure and temperature). The refrigerant also absorbs the heat of the compressor motor, and this
heat is given off to the surrounding air by the condenser (2) – in the form of waste heat – by means
of the two fans (3).
The refrigerant is thus liquefied and passed to the inlet of the expansion valve (5) via the liquid
receiver (pipe expansion), the filter drier (7) and the sight glass (6). The expansion valve permits
liquid refrigerant to enter the evaporator as a function of the temperature.
Block flow diagram, Refrigeration Circuit
1. Compressor
2. Condenser
3. Fan
4. Evaporator
5. Expansion valve
6. Sight glass
7. Filter drier
8. Pipe expansion (receiver)
9. Hot gas bypass valve

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2.3 Water Circuit
The water circuit of the P030 Chiller together with the connecting hoses constitutes the transport
system of the cooling water between the P030 Chiller and the primary circuit of the system
separator (COO). This closed water circuit is designed in accordance with requirements and is
equipped with all fittings and components required for safety and monitoring purposes. The water
circuit is provided with its own pump.
2.4 Cooling Air Supply
The heat transferred to the evaporator upon cooling the water as well as the heat generated by the
compressor motors are absorbed by the refrigerant and given off to the cooling air in the
condenser. As cooling air the ambient air is used which is drawn through the condenser by the
fans; the air is warmed in the process and then discharged in upward direction.
Caution!
•It must be ensured that the cooling air can be drawn in and discharged without
any obstruction and adequate air changes for heat dissipation away from the
installation site of the chiller can take place.

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2.5 Safety Devices
The P030 Chiller is equipped with the following safety devices:
High-pressure control (HP)
The high-pressure control is designed to protect the P030 Chiller against extremely high operating
pressure in the refrigeration circuit. In the event of a malfunction, the HP control switches the P030
Chiller off and the malfunction is indicated on the control panel of the control and operating unit.
The P030 Chillers cannot be restarted until the pressure has dropped to the preset pressure
difference and the Reset button on the high-pressure pressostat has been pressed. The pressostat
is accessible from the service side.
Power disconnect switch (main switch)
In an emergency, the P030 Chiller must be switched off by means of the main switch.
2.6 Monitoring Devices
Low-pressure control (LP)
The low-pressure control protects the P030 Chiller against extremely low operating pressure in the
refrigeration circuit. In the event of a malfunction, the control switches off the P030 Chiller, and the
malfunction is indicated on the control and operating unit. Restarting of the P030 Chiller is effected
automatically as soon as the pressure has risen by the preset pressure difference.
Compressor overheat protection
Each compressor is equipped with an overheat protection (thermal contact, Klixon). In the event of
an increase in motor current in conjunction with a rise in the winding temperature, the overheat
protection trips, and the compressor is switched off. The overheat protection resets itself
automatically after the windings have cooled down. This malfunction is not indicated on the control
and operating unit.
Thermal contact – fan motor
In the event of an increase in motor current in conjunction with an increase in winding temperature,
cooling operation is switched off by the thermal contact. This malfunction is indicated on the control
and operating unit.
Circuit breakers (compressor, fan, pump)
In the event of an increase in motor current or in the case of short circuits, the circuit breaker trips
and interrupts the power supply. Such malfunctions are indicated on the control panel. The circuit
breakers are located in the control cabinet.
Flow and pressure switches in the water circuit
The flow switch shuts off the pump when the preset volume flow limit value is fallen short off and
sends a corresponding signal to the control and operating unit.
The pressure switch does not signal the malfunction to the control and operating unit if a pressure
increase in the water circuit exceeds the preset value.
Fan control
The condensation pressure is controlled by cycling the individual fans on and off. This type of
control permits an adaptation to different operating conditions at relatively constant condensation
temperatures.

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Control and operating unit
The control and operating unit controls the water circuits and the refrigeration circuit. The control
and operating unit with display of the water temperature as well as the error codes in the case of a
general fault alarm is integrated in the control cabinet door.
2.7 Electrical/Control Equipment
The electro-technical equipment of the P030 Chiller is installed in the control cabinet. All required
components for the automatic switching, controlling and regulating operation are contained in the
control cabinet.
The main electric circuits are of a non-fused design featuring motor protecting switches.
The water outlet temperature is kept constant by the control and operating unit at a given setpoint
value by activation of power stages in the refrigeration circuit. The current water outlet temperature
is displayed on the control and operating unit.
The connection of the P030 Chiller to the equipment to be cooled is effected via a potential-free
interface. To achieve a galvanic isolation of the equipment to be cooled and the P030 Chiller, the
connection is accomplished by means of optical-fibre cables.

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3 TECHNICAL DATA
3.1 Hydraulic Data
Description Unit Values
Designation: P030 Chiller
Type 2NK6 772 C
Cooling capacity kW 37
Cooling medium, primary
circuit water/glycol mixture
60 %/40 %
Cooling medium outlet
temperature °C 9 ± 3 K
Operation volume flow,
cooling medium m
3
/h 3
Max. operating pressure
(against closed valve) bar 3.8 at 50 Hz
5.4 at 60 Hz
Max. allowable pressure
(cooling medium circuit)
bar 10
3.2 Electrical Data
Values
Description Unit 50 Hz 60 Hz
Operating voltage V/Ph/Hz 400/3/50 460/3/60
Power input, overall
system kW 28 34
Max. current draw A 50 54
Fuse protection at site A max. 63 max. 63
3.3 General Data
Description Unit Values
Connections mm M36 x 2 / DN 25
Dimensions W x H x D mm 1640 x 1953 x 841
Weight kg 606

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3.4 Name Plate
Name Plate
3.4.1 Installation Location of the Type Plate
The name plate is attached to the front of the control cabinet, at the bottom on the right.
Location of the name plate and the barcode identification label
Barcode
identification
label
Name plate

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4 TRANSPORT AND STORAGE
Caution!
•The safety notices contained in Chapter 1 must be complied with! As a rule, the
P030 Chiller must be transported in upright position without water charge!
•Stacking the units may result in serious accidents and damage to the units and
is, on principle, not permitted!
•Damaged units must be sorted out immediately!
The in-house transport is carried out by a forklift, lift truck or crane. The P030 Chiller must be
deposited on a level surface to prevent any distortion of the base-frame.
4.1 Transport Specification
−Weight (see Chapter Technical Data)
−Main dimensions (see Chapter Technical Data)
−Ambient temperature range: –20°C to +60°C at a rel ative humidity of 10 to 90 %.
In ambient temperatures <0°C the water circuits mus t be completely drained, including pumps and
pressure vessel.
(See Chapter Decommissioning)

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4.2 Transport Using a Forklift
To move the P030 Chiller with a fork lift, the recesses provided at the broadside of the base-frame
of the unit should exclusively be used. Do not lift the unit until the forks have been inserted
horizontally all the way beneath the unit, symmetrically to the centre of gravity of the P030 Chiller.
Recesses, Transport with Forklift
Caution!
•The lifting rate should be kept to a minimum!