OWNERS MANUAL - Fleming Chillers
Contents
1. FLEMING Dynamic Chillers Your process water chiller specialist coolpak OWNERS MANUAL COOLPAK CP AIR COOLED RANGE MODEL PURCHASED SERIAL NUMBER SERVICE PHONE 1300 730 736 coolpak coolpak Sydney Melbourne nsw fleming net au vic fleming net au PO Box 638 PO Box 2119 Australia Ph 1300 730 736 Balgowlah NSW 2093 Moorabbin VIC 3189 Australia Fax 1300 730 739 20 32 Roseberry Street Shop 5 2 10 Central Avenue New Zealand Ph 0800 442 569 Balgowlah NSW 2093 Moorabbin VIC 3189 www fleming net au Fleming Dynamics Pty Ltd ABN 55 002 230 266 FLEMING Your process water chiller specialist Ocoolpak Contents Page 1 KEE 2 2 AD me EE 2 3 Installation Position OF CHIET EEN 3 4 MaE E O T 4 5 Sleeve lee Te e 5 6 Salle ge gh UD EE 6 7 Digital Temperature Conor 7 8 Temperature Set point adjustment ooccococ o coco coco o oco c oc coco c 7 9 BE ent Sa COD Cy T UU UU n 8 9 L0 TPOUBDIGSHOOUNG is 10 11 Refrigeration Schematic of air cooled Chiller 12 12 KEE 13 Supplied separately 13 Electrical drawings CP5 to CRU uxxxk KKK NNN NNN NN KEREN NR NNN NNN NN KEE R REN NN NNN KEN 13 14 Electrical drawings CP20 to CPIS O NEEN 14 Page 1 FLEMING Your process water chiller specialist 1 Overview Thank you for selecting a Coolpak process water chiller In order to use the chiller correctly and efficie2. by a licensed Electrician On power up please check the phase rotation and or loss relay have both an orange light and green light for the initial start up If both lights on the phase relay are not illuminated the system will NOT START If both lights are not on then one of the three phases must be rotated or each phase must be tested for presence Single phase machines Voltage 220 240V 50HZ L is the line phase active the neutral wire is N and the earthed wire is E On three phase machines voltage 415V 50HZ the phase terminals are R S T Only a neutral connection may be required pending the capacity of the machine It is important to check if the terminal strip as a neutral terminal The chilled water piping must be connected to the machine that it serves with suitably sized water pipe and insulated pending the operating temperature of the machine Before starting the water pump please ensure that water has been added to the system and that the air has been bled To bleed the air from the pump the nut must be carefully loosened on the pump housing to enable the air to escape from the system Once the pump has started is should be carefully checked for the correct running direction to ensure correct operation The chiller must not be placed close to machines or plant equipment emitting high quantities of heat Check that none of the air inlets in front of the condensers are covered Page 5 6 FLEMING Your process water chi
3. e options include Water Cooled Condenser Closed systems without tank Close Tolerance on water supply temperature 0 1 C Tandem configurations slave master Web Enabled amp microprocessor control Flood back prevention Remote fault indication amp switching JO Un BR WN FE Page 13
4. es at the first available opportunity Please do not hesitate to ask any questions pertinent to the chiller by contacting Fleming Dynamic Chillers specifying the serial No as indicated on the nameplate 2 Application Coolpak is designed to meet the cooling requirements of all machinery and processing equipment across all industry When in operation water of a controlled temperature is circulated through the cooling channels of the process The process connected to the chiller must be able to stand the maximum pump pressure of the chiller In the standard range the temperature range is 7 C to 30 C Page 2 FLEMING Your process water chiller specialist 3 Installation Position of chiller When installing indoors it is important to provide ample space around the chiller in order for the system to breathe as it will reject significant amounts of heat The condenser inlets must have sufficient air supply and hot air from exhaust cannot be sucked back into the chiller as this will reduce the chillers performance If the chiller is placed in a small room with low floor to ceiling height the hot air must be ducted from the room and the chiller The cross section of the air duct must be at least the same size as the air outlet s of the chiller 900 M Page 13 FLEMING Your process water chiller specialist 4 Maintenance The power supply must be switched off before cleaning the chiller The condenser should be clea
5. ing motor or pump The overload relay is too Small or its set value is too low Bad circuit joint The protection device has shut itself off Replace fuse Replace reverse relay If all these items are working the overload switch may be faulty Exchange any two phases of the power supply Test the three phase source with a multimeter Check power supply Please deal with the problem according to Footnote 1 clean the condenser Replace pressure switch Deal with the problem according to Footnote 2 Check whether the expansion water tank is low on water and the circulating pump is running or not if that is not the problem the chiller should be stopped and restarted or reset the low pressure switch by pressing RESET If the evaporator has frozen douse with warm water to melt the ice after drawing off the iced water Replace evaporator or repair it Note Do not use hard implements to break the ice because that could damage the copper tube or damage the compressor Decreasing or unstable voltage Adjust the voltage and check for missing phase Replace bearing Deal with the problem according to Footnote 1 Change to larger overload relay or adjust the normal value higher Please deal with the problem according to Footnote 4 Waterinthe Jj 0 Page 10 FLEMING Your process water chiller specialist water tank will The chiller is undersized Replace with a higher capacity not cool o
6. ller specialist Chiller start up Press the ON OFF button to start the chiller When the green RUN indicator light illuminates the chilled water pump is started The start of the compressor and the condenser fan is delayed whereby if there is one compressor the delay is approximately 3 minutes If there are two compressors the second compressor will start shortly after the first The pump will run continuously and the return chilled water temperature will be monitored and compared with the temperature set point When the temperature rises 2 C above the set point the compressor and condenser fan will be started If the red fault light appears either the pump and or the compressor will be stopped immediately Please refer to the fault table at the rear of this manual To shut down the system press the ON OFF button to turn off the machine If the system is not in use for a long period of time we recommend that the power be isolated and the cooling media drained from the tank Page 6 7 FLEMING Your process water chiller specialist Temperature Controller Temperature Controller Operation H CO DH Display shows the value measured by the connected temperature sensor In the event of an alarm condition the sensor value will be displayed alternately with the codes of the active alarms When programming the controller the display shows the parameter codes being introduced and their values Deci
7. mal Point LED lights up when the controlled parameter is displayed Reverse LED This is not applicable to our range of equipment Direct LED flashes when the compressor and condenser fan has been enabled Temperature Set point adjustment SEL Button displays and or allows you to select the Set point To change the Set point press the SEL button Use the up A and down V arrow buttons to change the value Once the temperature Set point has been changed push the SEL button to hold the Set point change and return you to the main display PLEASE NOTE We strongly recommend that this temperature be set not less than 10 C as it is displaying the return chilled water temperature Page 7 FLEMING Your process water chiller specialist 9 Technical Table All cooling capacities are based on an ambient operating environment of 40 C MODEL CP 3 CP 5 CP 7 CP 12 CP 15 CP20 Power Reguirement 1PH 240V 50Hz 3PH 415V 50Hz Three Phase Plus Neutral Type R407C Type of control TX Valve Type hermetic rotary hermetic scroll Compressor condenser Air flow m h 1000 2000 3000 5000 6000 8000 Inlet Outlet T Type Stainless Steel Coil in Stainless steel tank Pump Flow I h 560 2120 2120 2650 4470 4470 350 SC Length mm height rm 2 20 Page 8 MODEL Cooling capacity 5 c Cooling capacity 10 c Cooling capacity 15 C Cooling capacity 20 C Input power Power Requirement Maximum c
8. ned frequently by blowing compressed air in the opposite direction to that of the air direction of the fan The cleaning interval depends on the location of the chiller We strongly recommend all Coolpak customers to consider a preventative maintenance service by our trained Coolpak technicians to ensure the chiller remains in peak operational condition This eliminates costly down time and increases the operational life of the chiller Standard annual preventative includes approximately four to six hours onsite labour plus associated cost for induction consumables or company regulation PPE personal protection equipment Our standard preventative maintenance consists of the following checks e Operation Frequency e Clean Condenser Coil 6 monthly e Check For Evidence Of Moisture In Refrigerant 6 monthly e Check For Refrigerant Blockages 6 monthly e Check For Evidence Of Refrigerant Leaks 6 monthly e Check Refrigerant Operating Pressures 6 monthly e Check Flow Rates amp Pressure In Water Circuit 6 monthly e Check For Integrity Of Electrical Connections 6 monthly e Check Current Draw On All Motors 12 monthly e Clean Out Buffer Tank 12 monthly Page 14 5 FLEMING Your process water chiller specialist First Time Operation Before first time operation please confirm the following de 2 10 11 Check the nameplate to confirm the correct supply voltage The electrical connection to the Chiller must be carried out
9. ntly please read the following instructions in detail This chiller is designed to be safe provided that it is installed operated and maintained correctly The chiller contains electrical and moving components It therefore must be isolated from the electrical supply before commencing installation works All maintenance must be carried out by suitably qualified technicians who have a good knowledge of all necessary precautions associated with refrigeration equipment The liquids to be cooled must be suitable for the application of the chiller and we strongly recommend that the liquids used are water or mixtures of glycol and water The cooling medium must not contain any flammable substances The chiller contains refrigerants under pressure If the chiller is no longer required it is essential that the refrigerant is reclaimed from the unit before disposal If the chiller is placed out doors it must be undercover for protection against direct rain and Sunlight Connection hoses must be suitable for the minimum and the maximum temperature and maximum pressure of the chiller Fleming Dynamic Chillers cannot be held responsible for liabilities created by substandard electrical wiring and installation practices external to the chiller Every chiller is crated prior to shipment to avoid damage in transit Before accepting delivery check the overall equipment condition for any visible damage The chiller should be inspected for hidden damag
10. r the Low refrigerant machine low pressure The water tank is Deal with the problem according to switch has shut contaminated by the Footnote 3 off refrigerant gas Clean tank re gas after dealing with Damaged valve the problem with drying agent for the Temperature is set too high expansion valve while in vacuum Faulty temperature indicator Change the compressor check Faulty temperature sensor according to Footnote 3 Adjust the temperature lower Replace switch If the efficiency is low it can be dealt according to Footnote 1 Replace sensor Low Water level e Insufficient water in tank e Add water into the water tank e Low water flow e Check that each valve is fully open Page 11 Your process water chiller specialist Refrigeration Schematic Air Cooled Chiller 11 ISirewads op saem 9301d INO Sau DIWIBUAG eu uopgiefuen lt yng eM enes einsseig JejeM PL 9NBA XL Z ssed Ag EL 1e aq eur pinbry 9 duing eBeysninw ZU s ue Jesuepuo G yu eas SSOJUIEJS LL Jesuepuo p Jejjouo eunjejeduie jey6iq 9 eunsseud YBIH MO IND dH E o e119 jeM MO1 6 eunsseud MOT INO IND d1 Z JojeJode 3 g Josseidwo QN3931 Sse00 d OL SS 90Jd WOJ JILVW3HOS NOILViH39 RH 334 131002 IV AVd 1002 Page 12 FLEMING Your process water chiller specialist 12 Chiller options Coolpak has a range of options and in many cases is custom designed to suit the application Som
11. urrent draw Refrigerant Compressor condenser Evaporator Tank Volume Pump Dimensions L W H Weight A Type KG Type of control Type Power KW Air flow m h Water flow m h Inlet Outlet connections Type Ltr Flow I h Pressure kpa kw Length mm width mm height mm Kg FLEMING Your process water chiller specialist CP 25 CP 30 CP 40 CP 50 CP 60 CP 80 CP 100 CP 130 sere ara ses eoe eos ooo wos 7 3PH 415V 50Hz Three Phase Plus Nuetral R407C TX Valve hermetic scroll Copper Coil in Stainless steel tank ei s10 990 nao 1180 no 1500 1700 Page 9 10 Troubleshooting FLEMING Your process water chiller specialist Power connected jw but unit cannot be operated Overload is activated Reverse phase Over temperature indicator is on Low refrigerant Overload and the fault indicator is lit The fault indicator is not on but the compressor is not running Check Fuse Faulty Reverse relay Power supply has grounded or short in electrical circuit Faulty compressor pump or motor Pump compressor or fan is running reversed Missing one phase The high pressure switch has shut off The high pressure switch is faulty Low pressure switch has shut itself off due to low refrigerant level Evaporator has frozen Faulty temperature controller or transducer Abnormal voltage Damaged compressor bear
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