OWNERS MANUAL

COOLPAK CP AIR COOLED RANGE

MODEL PURCHASED

SERIAL NUMBER

SERVICE PHONE 1300 730 736

Contents

Page

Overview ............................................................................................................ 2 1)

2)

3)

4)

Application .......................................................................................................... 2

Installation Position of Chiller ................................................................................ 3

Maintenance ....................................................................................................... 4

5)

6)

7)

8)

First time operation ............................................................................................. 5

Chiller start up .................................................................................................... 6

Digital Temperature Controller .............................................................................. 7

Temperature Set-point adjustment ........................................................................ 7

9) Technical table ................................................................................................. 8-9

10) Troubleshooting ................................................................................................. 10

11) Refrigeration Schematic of air cooled chiller ........................................................... 12

12) Chiller options .................................................................................................... 13

Supplied separately

13) Electrical drawings CP5 to CP15 ............................................................................ 13

14) Electrical drawings CP20 to CP130 ........................................................................ 14

Page | 1

1)

Overview

Thank you for selecting a Coolpak process water chiller. In order to use the chiller correctly and efficiently, 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 damages 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

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

600 M

600 M

Page | 3

Maintenance

4)

The power supply must be switched off before cleaning the chiller. The condenser should be cleaned 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

• Operation

Frequency

• Clean Condenser Coil

6 monthly

• Check For Evidence Of Moisture In Refrigerant

6 monthly

• Check For Refrigerant Blockages

6 monthly

• Check For Evidence Of Refrigerant Leaks

6 monthly

• Check Refrigerant Operating Pressures

6 monthly

• Check Flow Rates & Pressure In Water Circuit

6 monthly

• Check For Integrity Of Electrical Connections

• Check Current Draw On All Motors

•

Clean Out Buffer Tank

6 monthly

12 monthly

12 monthly

Page | 4

5)

First Time Operation

Before first time operation, please confirm the following:

1. Check the nameplate to confirm the correct supply voltage.

2. The electrical connection to the Chiller must be carried out by a licensed Electrician

3. 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.

4. If both lights are not on then one of the three phases must be rotated or each phase must be tested for presence.

5. Single phase machines Voltage: 220~240V/50HZ; L is the line phase (active) the neutral wire is N and the earthed wire is E.

6. 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

7. 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.

8. 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.

9. Once the pump has started is should be carefully checked for the correct running direction to ensure correct operation.

10. The chiller must not be placed close to machines or plant equipment emitting high quantities of heat.

11. Check that none of the air inlets in front of the condensers are covered.

Page | 5

6)

Chiller start up

1. Press the "ON / OFF" button to start the chiller. When the green RUN indicator light illuminates, the chilled water pump is started.

2. 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.

3.

4.

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 o

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.

5. 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)

Temperature Controller

Temperature Controller Operation

Display: shows the value measured by the connected temperature sensor. In the event of

1 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.

2

3

4

Decimal 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

8)

Temperature Set-point adjustment

5

SEL Button: displays and/or allows you to select the Set-point. To change the Set-point press the SEL button .Use the up ▲ and down ▼ 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 o

C as it is displaying the return chilled water temperature.

Page | 7

9)

Technical Table

All cooling capacities are based on an ambient operating environment of 40°C.

MODEL

Cooling capacity @ 5°C

KW

Cooling capacity @ 10°C

KW

Cooling capacity @ 15°C

KW

Cooling capacity @ 20°C

KW

KW Input power

Power Requirement

Maximum current draw A

Type

Refrigerant

Compressor condenser

Evaporator

KG

Type of control

Type

Power (KW)

Air flow (m

3

/h)

Water flow (m

3

/h)

Inlet/Outlet connections

Type

Tank Volume

Pump

Dimensions L/W/H

Ltr

Flow (l/h)

Pressure (kpa) kw

Length (mm) width (mm) height (mm)

Weight Kg

CP-3

2.38

2.47

2.57

3.24

1.42

1PH - 240V - 50Hz

6.9

1

20

560

350

0.45

750

550

800

85

CP-5

4.75

5.2

5.67

CP-7

6.84

7.6

8.55

CP-12

11.4

12.45

14.13

CP-15

13.49

15.01

17.01

CP20

18.05

19.95

23.4

6.48

2.35

10.17

3.55

16.38

5.85

18.9

6.36

27.9

9.31

4.7

3PH - 415V - 50Hz (Three Phase Plus Neutral)

5.8 9.4 10.9 15.5

2

R407C

2.3

TX Valve

3.6 4.5 2.8*2

1.52 2.68 hermetic scroll

4.63 5.2 3.43*2

2000 3000 5000 6000 8000

1.53 1.53 2.55 3.02 3.93 hermetic rotary

0.89

1000

0.56

1/2" 1/2" 1" 1" 1"

Stainless Steel Coil in Stainless steel tank

40

2120

350

0.56

930

520

975

100

50

2120

350

0.56

1020

520

975

135

70

2650

350

0.66

1140

560

1040

175

70

4470

350

1

1140

560

1040

180

1"

120

4470

350

1

1310

720

1270

310

Page | 8

4.63*2

10000

5.11

1"

200

5300

350

1.1

1680

810

1280

450

CP-25

22.8

24.89

28.26

32.76

12.5

17.9

3.6*2

200

6900

350

1.29

1680

810

1280

530

CP-30

26.98

30.02

34.02

37.8

CP-40

30.4

34.2

38.16

46.8

CP-50

43.7

49.4

56.16

63.36

CP-60

53.2

60.8

68.4

80.1

CP-80

65.5

74.1

85.14

90.9

13.65 17.2 22.05 24.29 33.4

3PH - 415V - 50Hz (Three Phase Plus Nuetral)

20.2 26.7 35.7 38.7 54

CP-100 CP-130

87.4

100.7

117

140.4

43

104.5

115.9

144

171

54

72 86.1

4.5*2

5.2*2

12000

5.89

6*2

R407C

7.5*2 9.2*2 11.3*2

TX Valve hermetic scroll

9*2 10.1*2 13.6*2 6.75*2

15000 20000 25000 30000

7.86 10.22 10.22 16.33

14.5*2

17.7*2

40000

21.29

18.6*2

22*2

50000

26.3

1-1/2" 2" 2" 2-1/2" 2-1/2" 2-1/2" 3"

Copper Coil in Stainless steel tank

270 350 350 420 580

8200 10800 10800 20000 20000

350

1.56

350

2.15

350

2.15

350

4

1800 2000 2000 2200

350

4

2000

990 1130 1130 1100

1680 1720 1914 2000

750 835 920 1150

1500

2000

1350

580

31800

350

5.5

2200

1700

2000

1600

Page | 9

10)

Troubleshooting

State

Power connected but unit cannot be operated

•

•

Reason

Check Fuse

Faulty Reverse relay

Overload is activated

Reverse phase

•

Power supply has grounded or short in electrical circuit.

•

Faulty compressor, pump or motor.

•

Pump, compressor or fan is running reversed

•

Missing one phase

Solution

• Replace fuse

• Replace reverse relay

• If all these items are working, the overload switch may be faulty

Over temperature indicator is on

Low refrigerant

Overload and the fault indicator is lit

•

•

•

•

•

•

Abnormal voltage

•

Damaged compressor bearing, 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.

• 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

The fault indicator is not on, but the compressor is not running

Water in the

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

Page | 10

water tank will not cool, or the low pressure switch has shut off

• The chiller is undersized

• Low refrigerant

• The water tank is contaminated by the refrigerant gas

• Damaged valve

• Temperature is set too high

• Faulty temperature indicator

• Faulty temperature sensor

• Insufficient water in tank

• Low water flow

• Replace with a higher capacity machine

• Deal with the problem according to

Footnote 3

• Clean tank, re-gas after dealing with the problem with drying agent for the expansion valve while in vacuum

• Change the compressor, check 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

• Add water into the water tank

• Check that each valve is fully open

Low Water level

Page | 11

11)

Refrigeration Schematic - Air Cooled Chiller

Page | 12

5.

6.

7.

12)

Chiller options

Coolpak has a range of options and in many cases is custom designed to suit the application.

Some options include

1. Water Cooled Condenser

Closed systems without tank 2.

3.

4.

Close Tolerance on water supply temperature +/- 0.1°C

Tandem configurations – slave master

Web Enabled & microprocessor control

Flood-back prevention

Remote fault indication & switching

Page | 13