KLH SC 2 Betriebshandbuch

14.12.2011 / 01.00

Am Waldrand 10

D-18209 Bad Doberan

Tel +49 38203 96 0

Fax +49 38203 96 62

E-mail: info@klh.selckgroup.com

Internet: http://www.klh-kaeltetechnik.de

Translation of the original Operating Manual

Operating Manual

Refrigerating Set

SC 2

KLH Kältetechnik GmbH

u n i v e r s a l c h i l l e r s

Read the operating manual before start working!

Keep the operating manual carefully for further usage!

KLH Kältetechnik GmbH

u n i v e r s a l c h i l l e r s

ENGLISH

- 2 /31- 14.12.2011 / 01.00

Ordering Information

Please indicate the title of the operating manual, your language, and the

date of issue.

KLH Kältetechnik GmbH

D-18209 Bad Doberan

Am Waldrand 10

Telefon +49 38203 96 0

Telefax +49 38203 96 62

E-mail info@klh-kaeltetechnik.de

Internet http://www.klh-kaeltetechnik.de

This document has been established by the Technical Documentation

department of KLH Kältetechnik GmbH.

All rights in respect of this documentation, in particular the rights to

duplicate, distribute and translate it are reserved by KLH Kältetechnik

GmbH, including in the event of industrial property rights applications. No

part whatsoever of the documentation must be reproduced or processed,

duplicated or distributed with the use of electronic systems, in any form,

without the prior written consent of KLH Kältetechnik GmbH. Errors

excepted. Subject to technical modifications.

KLH Kältetechnik GmbH does not assume any liability for any mistakes in

this documentation. Any liability for any indirect and direct damage

occurring in connection with the delivery or the use of this documentation.

We guarantee on this cooling devices, filled with necessary quantity of

refrigerant by manufacturer, checked regarding tightness and examined

by a test run a respective guarantee according our contract declaration

assuming a professional use (skilled persons, keeping maintenance

intervals and operating the cooling device according to the pre-scribed

parameters).

Any claim expires in case the points of this operating manual are

neglected.

Guarantee/Warrenty

KLH Kältetechnik GmbH

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Attention:

This equipment must run with water-glycol- solution as protection

against corrosion and frost protection (AFL)!

Ratio of mixture: 25 : 75 %

Serial No.:

Works No.:

Year of manufacture:

To be entered by the user:

Inventory number:

Installation side:

Edition:

12/2011

SC2.K1W.MT

Type:

50 Hz

60 Hz

Dual frequency

voltage

50Hz / 60Hz

KLH Kältetechnik GmbH

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Table of contents

1. For your safety 5

1.1 Regulations 5

1.2 Signs and symbols 6

1.3 Security advice 7

1.4 Purpose 7

2. Description of the refrigerating set 8

2.1 Water-bearing equipment 8

2.1.1 Cooling circuit 9

2.2 Cooling equipment 10

2.2.1 SC 2 (water-cooled) 10

2.2 Electrical / Control equipment 11

2.4 Safety / Monitoring equipment 12

2.4.1 Safety devices 12

2.4.2 Monitoring devices 12

3. Technical data 13

4. Transport 14

4.1 Transport -Crane 14

4.1 Transport specification 14

5. Storage 14

6. Installation 15

6.1 Indoor installation 15

7. Connection of the refrigerating set 16

7.1 Connection –Water piping 16

7.2 Connection –Electrical system 16

7.2.1 Main feeding 16

7.2.2 Signal interface 16

8. Start-up 17

8.1 Start-up 17

8.1.1 Water Requirements 18

8.2 Placing out of service 18

8.3 Environment requirements 18

9. Operation 19

10. Maintenance 20

10.1 Repetition test 21

11. Fault / Trouble shooting 22

11.1 Malfunctions at the temperature controller 22

11.2 Displays 22

12. Dimension 23

13. Flow diagram 24

14. Spare parts list 25

15. Declaration of Conformity 26

16. Pump Characteristic Line 27

17. Description Temperature Controller 29

18. Abbreviated instructions 31

19. Electrical diagram 32

Table of contents

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1. For your safety

1.1 Regulations

The construction and design of the process coolers are in compliance with

the following national and international regulations.

EG-recommendation

- EC Machinery Directive 2006/42/EWG

- EC Low Voltage Directive 2006/95/EG

- EC EMC Directive 2004/108/EG

- EC Pressure Equipment-Directive 1997/23/EG

European Standards (EN)

EN 378 Refrigerantion plants and heat pumps

- Safety-relevant and environmental requirements

Part 1 Basic requirements, definitions,

classifications, and applications

Part 2 Design, manufacture, testing, marking, and

documentation

Part 3 Place of installation and protection of staff

Part 4 Operation, maintenance, repair, and recovery.

EN 60529 Degrees of protection provided by enclosures (IP)

EN 12100/T1/T2 Safety of machinery

-Basic terminology, methodology

- Technical guidelines and specifications

EN 394 Safety of machinery

- Minimum clearances to prevent crushing of body

parts

EN 60204 Electrical equipment of machinery

EN 61000-6-4 Electromagnetic compatibility –generic emission

standard

- Generic specification „ Noise transmission „

- residential, commercial, light industry and

industrial environment

EN 6100-6-1 Electromagnetic compatibility –generic immunity

EN 6100-6-2 standard

- Generic specification „ resistance to jamming „

- residential, commercial, light industry and

industrial environment

National Regulation

BGR 500 Operating method of work equipment,

Operating method of work equipment concerning

refrigeration plants, heat pumps and cooling

equipment

1 For your safety

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1.2 Signs and symbols

Throughout this operating manual, the information and notices

below are identified by graphical symbols:

Premonitorily 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 or damage to

the equipment.

Advertently symbols:

Information !

This symbol identifies important information or a useful tip

concerning the application of the equipment.

Work procedure

This symbol identifies a work procedure.

Listing

This symbol identifies an enumeration or listing.

1 For your safety

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1.3 Security advice

For the installation and operation of the cooling machine, the following

regulations and safety notes have to be observed:

Any work on the process cooler may only be performed by

qualified personnel.

All relevant accident prevention regulations have to be observed.

The electrotechnical connections of the cooling machine must be

performed according to and conforming with all relevant VDE, EN

and IEC standards. Beyond that, the technical connection

requirements of the local electrical utility company have to be

observed.

Before attempting to carry out any work on the process cooler,

always disconnect the unit from the power supply.

. National standards applicable in the country where the unit is

installed must be complied with.

The safety equipment is not to be suspended.

Alterations of operation parameters of the cooling device are to be

carried out by authorised and introduced persons only.

The enclosed refrigeration cycle contains refrigerant and oil, which

must be disposed professionally (environmental care).

Cooling water additives have a caustic effect on the human skin

and eyes. When handling cooling water additives, wear eye-

protective glasses and safety gloves. Observe instructions on

product packing.

The operative range of the cooling machine has to perform

according to the determined technical data. (see chapter Technical

Data).

Watch out for any incompatibilities of materials in the entire water

circuit.

1.4 Purpose

Cooling machines are designed and constructed to keep the

temperature of a consumer medium constant within the determined

operation range by means of a cooling process (water at determined

quality or water with additives).

Operation has to be exclusively within the calculated load and operating

range.

1 For your safety

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2. Description

The cooler is of compact design. It consists of various functional sections including

the following subassemblies :

water-bearing equipment

cooling equipment

electrical / control equipment

safety / monitoring equipment

2.1 Water-bearing equipment

The heat generated at thecostumer machine is supplied to the cooler via water

circuit.

Inside the cooler, the circuit continues and equipped with the components

required.

TCI

20l

Rp 1/2"

Naming

Cooling water circuit

Evaporator

Pump

Tank

Float switch

Water level indicator

Discharge connection

Three-way valve

Pressure gauge

Temperature sensor

2 Description

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2 Description

2.1.1 Cooling circuit

Evaporator (5)

- Plate heat exchanger made of high-quality steel, copper soldered type.

Water tank (55)

- High-quality steel type, tank atmospheric open, covered, insulated for

condensation water, provided with discharge connection, water level

indicator, and built-in float switch for water level monitoring and filling.

Centrifugal pump (60)

- Multistage normal-suction horizontal high-pressure centrifugal pump of

block-unit design, made of plastics.

Pipe system

- Provided with fittings, madeof plastics hose (PUN-hose).

The heat generated at theload is supplied to the cooler via the cooling water

circuit. The cooling down of the water takes place in the evaporator (5) by way

of heat release. After cooling down, the cold water is supplied to thetank (55)

and is supplied back to the load via the pump (60) provided in the cooling

water circuit

(see also section 13- Flow diagram)

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2.2 Cooling equipment

2.2.1 SC 2 (water-cooled)

PZH

220

IG1/2"

The heat eliminated from the water circuits by means of an water-cooled cooling

machine. The cooling machine consist of a closed coolant circuit including all

components required. The coolant circuit circulates the coolant used as a working

medium.

Hermetic compressor (1)

- Hermetic compressor provided witha suction-gas cooled drive motor, motor protection by

means of an external monitoring module, oil-level glass, and external vibration-elastic

installation.

Water-cooled condenser (2/3)

- Plate heat exchanger, copper soldered type

Evaporator (5)

- Plate heat exchanger made of high-quality steel, copper soldered type

Pressure switch (HP)

- Pressure switch (High Pressure) (33)

Pipe system

- Closed pipe system madeof special copper tube, provided with collector (6) filter dryer (8)

and serviceconnections (20)

Inside theevaporator (5), the process heat generated is transfer from the water circuit to

the coolant circuit, at low evaporation temperature. It is then delivered to the condenser (2),

via compressor (1), together with thecoolant, in a gaseous condition. At the condenser, the

process heat is finally discharged to the water circuit.

The condenser pressure at the refrigeration circuit is constantly operated by the pressure

operated water valve.

Due to the heat release to the cooling water circuit, the coolant is liquefied and returned

to evaporator (5), via expansion valve (4).

Naming

Cooling equipment

circuit

Compressor

Condenser

Expansions valve

Evaporator

Tube expansion

Filter drier

Solenoid valve

Service connections

Pressure switch (HP)

Two-way valve

2 Description

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