S&A CWFL-500 User manual

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CWFL-500/1000/1500/2000/3000
Industrial Chiller
User Manual

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FOREWORD
Thanks for your purchase of our product. Please read this
manual carefully before using and keep it properly so that you can
refer to it whenever you need information.
This manual is not a quality guarantee. Our company reserves
the right to the interpretation of the correction of misprint and
improperly described information and product improvement. The
revised content will be edited into the reprinted user manual
without prior notice.

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CONTENTS
Notice---------------------------------------------------------------------------------------- 4
I. Overview--------------------------------------------------------------------------------- 7
II. Model Illustration -------------------------------------------------------------------- 7
III. Product Outlines & Parts--------------------------------------------------------- 8
IV. Installation----------------------------------------------------------------------------- 9
V. Operating States &Parameters Adjustment -------------------------------- 13
VI. Alarm & Output Terminal--------------------------------------------------------- 15
VII. Maintenance------------------------------------------------------------------------- 16
VIII. Simple Troubleshooting -------------------------------------------------------- 17
Attachment –Schematic --------------------------------------------------------------- 18

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Notice
In order to ensure your personal safety and avoid property loss, you must pay attention to
this manual, but not limited to the following warning notices. General electric knowledge
and safety standards should also be followed.
DANGER Failure to take safety measures will result in death or serious
personal injury.
Notice
Operation Guideline
The Operation should be
carried out by professional
technicians
Handling, installation of pipes, electrical, operation,
maintenance, overhaul and other operations must be
carried out by personnel with professional knowledge.
It is forbidden to be used
beyond the range of
specification
It is forbidden to use the equipment beyond the range of
manual specifications in order to avoid equipment
damage, injury, fire, electric shock and other major
accidents.
It is forbidden to be used in
the explosive environment
It cannot be installed in dangerous places with
flammable gas.
Electrical connection
a) The power supply must conform to the standard
indicated in the nameplate or the manual;
b) Use the standard cable, and select the standard wire
diameter;
c) The grounding wire must be installed and the
connection must be reliable; otherwise, it will cause an
electric shock or fire.
It is forbidden to operate the
equipment without a cover
There are live parts inside the machine. It is forbidden to
operate without a cover, as there is a risk of electric
shock.
Water-proof
Do not allow the equipment to be drenched or immersed
in water, otherwise there may be a risk of short circuit
and electric shock.
Maintenance and repair
The operation must be carried out after 3 minutes of
cutting off the power supply, because the high-voltage
charging part in the equipment is not discharged within 3
minutes. Working in a live state or working immediately
after shutdown will cause the risk of electric shock.
Danger
High Voltage
Contact with live parts can cause serious personal injury
or death.
Danger
Hot Surface
The human body or the heat-labile articles must keep
away from this high temperature area. Otherwise, it will
cause personal injury or property loss.

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DANGER Failure to take safety measures will result in death or serious
personal injury.
Notice
Operation Guideline
Transport and
installation
The equipment must be firmly fixed during transport and
installation. Otherwise, there will be a danger of tipping or
falling.
Electrical protection
The power cable terminal must be equipped with the electric
leakage and overload protection device according to the
rated current indicated on the equipment nameplate.
Stop running in
abnormal state
When the equipment is abnormal, as long as the cause is
not clear, it is forbidden to start. Otherwise, there is a danger
of damage, electric shock, fire, and injury.
Do not put fingers or
other things into the gap
of the equipment
There are rotating parts inside the device. Do not put fingers
or other things into the gap of the equipment. Otherwise, it
will cause personal injury.
Refrigerant leakage
a) When the refrigerant leaks, please make sure that the
ventilation is available. Otherwise, it may cause anesthesia
and suffocation if a large amount of refrigerant fills the
enclosed space;
b) Avoid contacting with skin, or it will cause frostbite.
DANGER Failure to take safety measures will result in minor personal
injury or property damage.
Notice
Operation Guideline
Transportation with
liquid is prohibited
The equipment is not allowed to be transported with liquid to
prevent internal pipeline leakage.
Transport
a) The equipment should be fixed firmly before transportation
to prevent the equipment from moving due to vibration and
external forces. If there is excessive vibration and external
force, the internal equipment may be damaged.
b) Tilt angle should be ≤45°.Otherwise, the refrigeration
system will fail.
Operating environment
a) It is forbidden to use in special environments such as high
temperature, humidity, strong electromagnetic interference,
etc.
b) The equipment must be installed in a place where there is
no direct sunlight and away from the fire sources.
Installation
a) The equipment must be installed on a horizontal surface.
Otherwise, the refrigeration system will fail;
b) It is forbidden to place objects within 1 meters around the
air inlet and 1.5 meters around the air outlet. If the air inlet

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and the air outlet are blocked, the cooling ability that the
equipment should have cannot be realized.
Before commissioning
a) Make sure that the water supply pipe of equipment is not
blocked;
b) It is necessary to check the water pipe and the water pump
to confirm that there is a proper amount of water entering the
water pump and exhaust it through the water pump exhaust
valve, otherwise it will cause damage to the water pump;
c) Confirm that the state of the equipment is normal and safe,
otherwise there may be injury and damage.
Gently move the motor
impeller if the
equipment isn’t used
for a long time
For equipment that has not been used for a long time, it may
be difficult to start the pump at the first start. Please gently
move the motor impeller before the equipment is powered on.
The equipment is
forbidden to be
trampled on
Please do not step on or sit on the equipment. Otherwise, it
may cause injury accidents such as falling or overturning
Clean the air filter
regularly
Clean the air filter at least once a week. If it is blocked, the
cooling ability will decrease and the power consumption will
increase, and the alarm will not work properly.
Equipment surface
cleaning
a) Please use cleaning agents that are non-corrosive to
metals and plastics;
b) Please keep the cleaning agent properly after cleaning to
prevent liquid leakage;
c) The container for storing the cleaning agent must be
sealed completely to avoid danger.
No air blowing at the
water outlet
A temp sensor is installed inside the water outlet, and it is
forbidden to blow air inside the device with an air gun.
Wear protective gloves
during maintenance,
inspection and cleaning
a) The sharp edges of the condenser fins may cut the skin;
b)The temperature of the internal compressor and refrigerant
piping is very high, and direct skin contact may cause burns.
Anti-freezing
a) When the ambient temperature is lower than 0℃and the
machine is shut down for a long time, it is necessary to drain
the liquid and blow the water away in the system with
compressed air, otherwise there is a danger of freezing and
cracking the components and pipelines.
b) When room temperature is lower than 0 ℃, it is
recommended to use antifreeze with a concentration of not
more than 30% containing ethylene glycol or propylene
glycol.

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I. Overview
This product is an industrial cooling device designed and manufactured for laser cutting,
laser welding, laser marking, laser engraving and other equipment that uses laser
processing. It can provide a temperature-stable cooling medium for the above application
scenarios.
The chiller is composed of a compressor, a condenser, a throttling device (expansion
valve or capillary), an evaporator, and a water pump. Its working principle is that the
chiller’s refrigeration system cools the water, and the water pump delivers the low-
temperature cooling water to the equipment that needs to be cooled. Then the cooling
water will take away the heat, heat up and return to the chiller, and then be cooled again
and transported back to the equipment. In the refrigeration system of a chiller, the
refrigerant in the evaporator coil absorbs the heat of the return water and vaporizes into
steam. The compressor continuously extracts the generated steam from the evaporator
and compresses it. The compressed high-temperature, high-pressure steam is sent to
the condenser and later will release heat (heat extracted by the fan) and condense into a
high-pressure liquid. After being reduced by the throttling device, it enters the evaporator
to be vaporized, absorbs the heat of the water, and the whole process circulates
constantly. Users can set or observe the working status of the water temperature through
the temperature controller.
II. Model Illustration
CWFL- 1000 A N
④Water pump
③Electric source type
②Chiller model series
①Chiller application
Note: This model description only contains the description of the company's main product
codes, not all of them are listed. Please confirm with our company before ordering the specific
model, our company has the final interpretation right about it.

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III. Product Outlines & Parts
Note: The above-mentioned product outlines and part names are only for one of the models. The
outlines and parts installation may be slightly different in different models.
Power Switch
Temperature Controller
(laser head circuit)
Temperature Controller
(laser circuit)
Water Pressure
Gauge
Air Inlet
(Filter Gauze)
Water Supply Inlet
Electrical
Connecting
Box
Water Outlet L
(laser circuit)
Air Outlet
Drain
Water Level Gauge
Alarm Output Port
Water Inlet L
(laser circuit)
Water Outlet H
(optics circuit)
Water Inlet H
(optics circuit)

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IV. Installation
1. Open the package and check whether the machine is in good
condition and whether the accessories are complete.
2. Please ensure that the working voltage of the chiller is stable and
normal.
Because the refrigeration compressor is sensitive to the power supply voltage, the normal
working voltage of our company's standard products is 210~240V (110V model is
100~120V). If wider operating voltage range is necessary, customization is available.
3. Equipment installation conditions and requirements.
(1) It must be installed on a horizontal surface and not tilted.
(2)The air outlet of the chiller should be at least 1.5m away from the obstacle, and the air
inlet must be at least 1m away from the obstacle (See below diagram).
(3) Do not install in harsh environments such as corrosive, flammable gas, dust, oil mist,
conductive dust, high temperature and humidity, strong magnetic field, direct sunlight, etc.
(4) Operating Environment
Ambient Temperature
Ambient Humidity
Altitude
0~45℃
≤90%RH
≤3,000m
(5) Medium Requirements
Cooling medium allowed by the chiller includes purified water, distilled water, high-
purity water and other softened water. It is forbidden to use oily liquids, liquids containing
solid particles, corrosive liquids, etc. Clean the filter element and replace the cooling
water regularly (about three months is recommended) to ensure the normal operation of
the chiller.
When the chiller is stored with water at room temperature lower than 2℃, it is
necessary to add anti-freezer in the chiller water tank. It is recommended to use
antifreeze with a concentration of not more than 30% containing ethylene glycol or
propylene glycol. After the temperature warms up, change to purified water, distilled water
or other suggested cooling media, let the chiller run for 30 minutes to remove the residual
anti-freezer and drain it, and then refill with unused circulating water.

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4. Determine the direction of the pipeline layout according to the water
inlet and outlet of the chiller, and ensure that the waterway is clean and
free of impurities, so as to prevent impurities from entering the
waterway and causing blockage or pump failure.
5. Plug in the power cord and turn on the power switch(It is forbidden to
start without water).
(1) After turning on the power switch, the circulating pump of the chiller starts to work.
When the new machine is turned on for the first time, there will be more air bubbles in the
pipeline, which will cause the machine to alarm occasionally, and it will return to normal
after a few minutes of operation.
(2) After starting the machine for the first time, check if the water pipes leaks immediately.
(3) After turning on the power, if the water temperature is lower than the set temperature,
it is normal that the cooling fan and other devices of the machine do not work. The
temperature controller will automatically control the working status of compressors,
solenoid valves, cooling fans and other components according to the set parameters.
(4) As it takes a longer time to start over the compressor and other components,
according to different conditions, the time is range from seconds to minutes, so do not
turn off the power and again on frequently.
6.Electrical connection.
(1) Please select the cable based on the max. rated current indicated on the label of the
chiller.
(2) Recommended reference standard for power cord diameter selection.
Rated current/ A
≤5
≤10
≤15
≤25
≤35
≤50
Wire diameter (copper wire)/ mm²
1.0
1.5
2.5
4.0
6.0
10.0
Note: This data is provided according to IEC 60204-1 standard and only for
reference. Standard cables must be used in the power cord.
(3) The main circuit of the power supply must be equipped with appropriate electric
leakage and overload protection devices, and the chiller must be well grounded.
(4) Less than ±10% of power supply voltage fluctuation and less than ±1Hz of frequency
fluctuation are allowed, and keep away from electromagnetic interference sources.
7. Fill Water & Exhaust Air.
(1) Fill Water
After the new machine is turned on, the air in the water pipe is emptied, and the
water level of the water tank will drop slightly. In order to keep the water level in the
green area, you can add water again. Observe and write down the current water level.
After the chiller has been running for a period of time, observe the water level gauge
again. If the water level drops significantly, check again if there is leakage in the water
pipes.

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(2) Exhaust Air
After adding water for the first time or replacing water, exhaust the air in the water pump
to start use, otherwise the equipment will be damaged. The exhaust method is as follows：
Method 1: Under the state of shutting down, after adding water, remove the water outlet
from the laser circuit (OUTLET L) and connect the water pipe, drain for 2 minutes, and
then install it firmly.
Method 2：Open the water supply inlet, after starting the machine (water flows),
repeatedly press and fold the water pipe several times to drain the air from the pipe.
Method 3: Loosen the air exhaust plug of the water pump (do not unscrew), and air is
discharged until water flows out, and then tighten the air exhaust plug
(See below diagram, only the exhaust position of the horizontal pump is shown.
According to customer requirements and specific models, the pump will be different, and
the exhaust position will also be different. For the specific situation, see the external
mark of the pump).
8.Test-run Check.
(1) Check whether the pipeline connection is correct, and there must be no bubbling or
water leakage;
(2) Check whether the inlet and outlet water ball valves are open and the drain valve is
closed;
(3) Check the liquid level of the water tank;
(4) Confirm that the electrical wiring of the equipment is connected correctly;
(5) Confirm whether the equipment is grounded.

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V. Operating States &Parameters Adjustment
The new T-506A intelligent temperature controller does not need to adjust the controlling
parameters under normal circumstance. It will self-adjust controlling parameters
according to room temperature for meeting equipment cooling requirements.
The new T-506B intelligent temperature controller is selected constant temperature
control mode as factory setting with water temperature at 25℃. User can adjust it as
needed.
T-506A and T-506B controllers are of same functions and structure except factory setting.
1.Temperature control panel introduction
(1) Indicators of temperature controller working status:
COMP ON, compressor working
SV ON, solenoid valve working
Heating ON, heating rod working
INT Ctrl ON, controller working in intelligent control mode
CT Ctrl ON, controller working in constant temperature control mode
PARAM Set ON, controller working in parameters setting mode
ALM OUT ON, alarm output status
Room Temp ON, displaying room temperature
ST DLA ON, starting up delay status
(2) Press key to show the room temperature(Room Temp light is on), press key to
show the real-time frequency value of the flow sensor，and 6 seconds later default
display restores.
(3) keys are for modifying parameters values and keys are for switching
parameter items.
(4) RST key: confirm
(5) SET key: setting function
2.Restore to factory settings
Before machine startup, press and hold keys until the controller displays rE.6
seconds after the keys are released, the controller works in normal status. All parameters
values settings of the controller have been restored to factory settings.

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3.Alarm function
(1) Alarm display:
When alarm occurs, the error code and the temperature will be alternately displayed.
(2) To suspend the alarm:
In alarming state, the alarm sound could be suspended by pressing any button, but
the alarm display remains until the alarm condition is eliminated.
4. General settings adjustment
Press SET key to enter into the user-defined state. Meanwhile, PARAM SET is on,
controller in parameters setup status.
(1).Under intelligent mode, the control panel displays the difference value between water
temperature and room temperature(default value is -2).
(2).Under constant temperature mode ，the control panel displays the set water
temperature value (default value is 25).
At this moment, press keys to change settings. After modifying the value, press
RST key to save and exit, then new parameters take effect. If there is no more action
within 20 seconds, it will automatically exit modifying status without saving parameters.
5. Advanced settings adjustment
(1) Press and hold the key while press SET key for 5 seconds until 00 displayed in
upper window and PAS in lower window. Then press keys to select the
password (default setting is 8), and then press the SET key, if the password is correct, F0
is displayed, entering into setup status and indicating that the controller is under
parameters setup status. If the password is incorrect, it returns to temperature display.
(2) Enter setup state, press keys to switch parameter items circularly, then press
keys to modify the parameter values. Press enter key RST at any time to exit
parameters setup with saving modified parameters and return to temperature display,
then chiller runs under the new parameters. If no key is pressed within 20 seconds, the
controller will automatically exit parameters setup without saving the modified parameters
(under parameters setup status, system running in original parameters). Under
parameters setup status, SET key does not work.
Note:
1.During parameters setting condition, system runs under original parameters.
2.Under constant temperature control mode, the water temperature is controlled by
parameter F0.
3.Under intelligent control mode, the water temperature will be automatically adjusted as
the room temperature changes. The temperature difference is commanded by F1.
E1
E2
E3
E4
E5
E6
E7
Ultrahigh
room
temperature
Ultrahigh
water
temperature
Ultralow
water
temperature
Room
temperature
sensor
failure
Water
temperature
sensor
failure
External
alarm
input
Water flow
alarm
input

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6.Advanced parameters adjustment case
Order
Code
Items
Value in Case 1
Value in Case 2
1
F0
Temperature setting
25
2
F1
Temperature Difference
Values
-3
3
F2
Refrigeration return
difference
0.5
2.0
4
F3
Way of control
1
0
5
F4
Alarm for over high
water temperature
15
5
6
F5
Alarm for over low
water temperature
15
10
7
F6
Alarm for over high
room temperature
45
45
8
F7
Password
8
8
9
F8
The allowed highest water
temperature
31
30
10
F9
The allowed lowest water
temperature
25
5
11
F10
Alarm of sensor pulse
frequency
8
8
Case 1:Cooling water temperature is controlled by intelligent control mode. Requiring
water temperature to be between 25℃to 31℃. The target water temperature is
3℃lower than room temperature. When room temperature remains, the water
temperature fluctuation shall not exceed ±0.5℃.There will be an alarm when
water temperature is 15℃lower or higher than target water temperature (e.g.
when room temperature is 30.0℃, cooling water temperature is between 27.5℃
to 26.5℃. If room temperature is up to 30.5℃, water temperature will be between
28.0℃to 27.0℃).
Case 2:Cooling water temperature is controlled by constant temperature control mode.
Requiring water temperature to remain at 25℃, and the water temperature
fluctuation does not exceed ±2℃. The alarm of over high water temperature will
be on when water temperature is 5℃higher than the set water temperature, and
the alarm of over low water temperature will be on when water temperature is 10℃
lower than the set water temperature. Users can easily adjust water temperature
between 5℃and 30℃through user setup.

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VI. Alarm & Output Terminal
In order to guarantee the equipment will not be affected while abnormal situation
happens to the chillers, the chillers are designed with alarm protection function.
1. Alarm output terminals and wiring diagram.
2.Alarm causes and working status table.
Note: The alarm output port is connected with a set of normally open and normally closed
contacts of the relay inside the machine. The working current should be smaller than 3A while
the working voltage should be smaller than 300V.
Display
Condition
Alarm
code
Buzzer
OUT H1、H2
OUT H1、H3
Circulating pump works
properly
DISCONNECTION
BREAKOVER
Ultrahigh room temp
E1
Sounds
BREAKOVER
DISCONNECTION
Ultrahigh water temp
E2
Sounds
BREAKOVER
DISCONNECTION
Ultralow water temp
E3
Sounds
BREAKOVER
DISCONNECTION
Faulted room temp sensor
（constant temp invalid）
E4
Sounds
BREAKOVER
DISCONNECTION
Faulted water temp sensor
E5
Sounds
BREAKOVER
DISCONNECTION
Alarm of water shortage
E6
Sounds
BREAKOVER
DISCONNECTION
Low flow rate /
water flow alarm
E6/E7
Sounds
BREAKOVER
DISCONNECTION
Faulted circulating pump
E7
Sounds
BREAKOVER
DISCONNECTION
Chiller power failure
BREAKOVER
DISCONNECTION

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VII．Maintenance
The equipment must be shut down for maintenance, and the power supply must be cut
off. The operation can only be carried out after 3 minutes, otherwise there will be a risk of
electric shock. When the room temperature is lower than 2°C, the internal water must be
drained when the machine is shut down for a long time.
1. Remove Dust Regularly
Regularly disassemble the filter gauze for cleaning and use a compressed air gun to blow
away the dust on the condenser (about 1 week is suggested and the air filter must not be
missing for a long time).
2. Guarantee Water Quality
A certain amount of impurities will accumulate in the filter element over a period of time,
which will cause a decrease in water flow, or even a secondary pollution. Therefore, it is
necessary to clean or replace the filter element regularly.

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VIII. Simple Troubleshooting
Failure
Failure Cause
Approach
Machine turned on but
unelectrified
Power cord is not plugged
in place
Check and ensure the power interface
and the power plug is plugged in
place and in good contact.
Fuse burnt-out
Open the electric box cover, check the
fuse and replace with a spare one if
necessary. Check whether the power
supply voltage is stable; Check and
ensure the power interface and the
power plug are in good contact.
Flow Alarm, Use a water pipe
to directly connect to the
water outlet and inlet but still
without water flowing
Water level in the water
tank is too low
Check the water level gauge display,
add water until the level shows in the
green area; And check whether water
circulation pipe leaks.
Flow alarm occurs while
chiller is connecting toother
equipment, but there is water
flowing and no alarm when a
water pipe is directly
connected to the chiller
water outlet and inlet.
Water circulation pipes are
blocked or a pipe bending
deformation.
Check water circulation pipe
Ultrahigh water temperature
alarm(temperature controller
displays E2)
Blocked dust gauze, bad
thermolysis
Disassemble and clean the dust gauze
regularly
Poor ventilation for air
outlet and inlet
To ensure a good ventilation
for air outlet and inlet
Voltage is extremely low or
unstable
To improve the power supply circuit or
use a voltage regulator
Improper parameter
settings on thermostat
To reset controlling parameters or
restore factory settings
Switch the power on and
off frequently
To ensure there is sufficient time
for refrigeration
(more than 5 minutes)
Excessive heat load
Reduce the heat load or use other
model with larger cooling capacity
Ultrahigh room temperature
alarm(temperature controller
displays E1)
The room
temperature is too high for
the chiller
To improve the ventilation to
guarantee that the machine is running
below 40℃room temperature.
Serious problem of
condensate water
Water temperature is much
lower than ambient
temperature, high humidity
Increase water temperature or
to preserve heat for pipeline
Water drains slowly from
drain port during water
changing
Water supply inlet is not
open
Open the water supply inlet
Startup flow alarm
Bubble in the water pipe
Exhaust the air

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Attachment –Schematic
CWFL-500/1000

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CWFL-1500/2000

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CWFL-3000