P030 Chiller Operating Manual

Original
OPERATING MANUAL
P030 Chiller
Glen Dimplex Deutschland GmbH

Geschäftsbereich RIEDEL Kältetechnik
Am Goldenen Feld 18
D-95326 Kulmbach
Phone: +49 (0) 9221 / 709 555
Fax: +49 (0) 9221 / 709 549
HEADQUARTERS GERMANY NORTH AMERICA

Phone: +49 (0) 9221 / 709 545 PARTS & SERVICE Phone: ++1-877 RIEDEL1
Fax: +49 (0) 9221 / 709 529 Phone: ++1-877 -743 -3351
Fax: ++1-734 -595 -9829
e-mail: service@Riedel-Cooling.com HOTLINE
http://www.Riedel-Cooling.com e-mail: service@riedel-usa.com
http://www.riedel-usa.com
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ENGLISH Translation of the Original
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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Translation of the Original ENGLISH
TABLE OF CONTENTS
1 FOR YOUR SAFETY .......................................................................................................... 5
1.1 REGULATIONS ...................................................................................................................................................5
1.2 SIGNS AND SYMBOLS ........................................................................................................................................6
1.3 SAFETY NOTICES ..............................................................................................................................................7
1.4 HANDLING OF REFRIGERANTS............................................................................................................................8
1.5 SAFETY REQUIREMENTS....................................................................................................................................9
1.6 PURPOSE OF THE P030 CHILLER .....................................................................................................................10
1.7 DECLARATION OF CONFORMITY .......................................................................................................................11
2 DESCRIPTION OF THE P030 CHILLER.......................................................................... 12
2.1 OVERVIEW P030 CHILLER ...............................................................................................................................12
2.2 REFRIGERATION CIRCUIT.................................................................................................................................12
2.3 W ATER CIRCUIT ..............................................................................................................................................14
2.4 COOLING AIR SUPPLY .....................................................................................................................................14
2.5 SAFETY DEVICES ............................................................................................................................................15
2.6 MONITORING DEVICES.....................................................................................................................................15
2.7 ELECTRICAL/CONTROL EQUIPMENT .................................................................................................................16
3 TECHNICAL DATA........................................................................................................... 17
3.1 HYDRAULIC DATA............................................................................................................................................17
3.2 ELECTRICAL DATA...........................................................................................................................................17
3.3 GENERAL DATA...............................................................................................................................................17
3.4 NAME PLATE...................................................................................................................................................18
4 TRANSPORT AND STORAGE......................................................................................... 19
4.1 TRANSPORT SPECIFICATION ............................................................................................................................19
4.2 TRANSPORT USING A FORKLIFT .......................................................................................................................20
4.3 TRANSPORT USING A LIFT TRUCK ....................................................................................................................21
4.4 TRANSPORT USING A CRANE ...........................................................................................................................22
4.5 STORAGE OF THE P030 CHILLER .....................................................................................................................23
5 INSTALLATION ................................................................................................................ 24
6 MOUNTING....................................................................................................................... 25
6.1 CONNECTION OF W ATER PIPING ......................................................................................................................25
6.2 ELECTRO-TECHNICAL CONNECTION .................................................................................................................26
6.3 OPTICAL FIBRE CONNECTION ..........................................................................................................................26
7 COMMISSIONING ............................................................................................................ 28
7.1 W ATER CIRCUIT ..............................................................................................................................................28
7.2 INITIAL START-UP OF THE PUMP ......................................................................................................................30
7.3 REFRIGERATION CIRCUIT.................................................................................................................................30
8 DECOMMISSIONING ....................................................................................................... 31
9 SHUTDOWN IN EMERGENCIES ..................................................................................... 32
10 ENVIRONMENTAL REQUIREMENTS ............................................................................. 33
11 OPERATION OF CONTROL AND OPERATING UNIT .................................................... 34
11.1 CONTROL AND OPERATING UNIT ST 181..........................................................................................................34
12 MAINTENANCE................................................................................................................ 36
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ENGLISH Translation of the Original
12.1 REPLACING FILTER ELEMENT .......................................................................................................................... 37

13 PERIODICAL INSPECTIONS AND TESTS...................................................................... 38
14 MALFUNCTIONS / TROUBLESHOOTING ...................................................................... 40
14.1 MALFUNCTIONS / TROUBLESHOOTING OF CONTROL AND OPERATING UNIT ST 181 ............................................ 40
15 OPTIONS .......................................................................................................................... 44
15.1 W ATER CIRCUIT.............................................................................................................................................. 44
15.2 ELECTRICAL SYSTEM ...................................................................................................................................... 44
15.3 COOLING AIR SUPPLY ..................................................................................................................................... 44
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Translation of the Original ENGLISH FOR YOUR SAFETY
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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FOR YOUR SAFETY ENGLISH Translation of the Original
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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DESCRIPTION OF THE P030 CHILLER ENGLISH Translation of the Original
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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Translation of the Original ENGLISH DESCRIPTION OF THE P030 CHILLER
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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Translation of the Original ENGLISH DESCRIPTION OF THE P030 CHILLER
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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Translation of the Original ENGLISH TECHNICAL DATA
3 TECHNICAL DATA
3.1 Hydraulic Data
Description Unit Values
Designation: P030 Chiller
Type 2NK6 772 C
Cooling capacity kW 37
Cooling medium, primary water/glycol mixture
circuit 60 %/40 %
Cooling medium outlet
°C 9±3K
temperature
Operation volume flow, 3
m /h 3
cooling medium
Max. operating pressure 3.8 at 50 Hz
bar
(against closed valve) 5.4 at 60 Hz
Max. allowable pressure
bar 10
(cooling medium circuit)
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
kW 28 34
system
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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TECHNICAL DATA ENGLISH Translation of the Original
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.
Name plate
Barcode
identification
label
Location of the name plate and the barcode identification label
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Translation of the Original ENGLISH TRANSPORT AND STORAGE
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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TRANSPORT AND STORAGE ENGLISH Translation of the Original
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.
Caution!
• The lifting rate should be kept to a minimum!
Recesses, Transport with Forklift
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4.3 Transport Using a Lift Truck

Handling the unit from the narrow side:
The P030 Chiller can be moved with a lift truck with the forks being inserted under the load from the
narrow side. To ensure that the forks can be inserted under both cross beams, a minimum fork
length must be maintained.
Caution!
Handling the unit from the broadside:

The forks of the lift truck must extend all the way through the unit, the fork rollers must project from
the other side of the unit. Only then may the P030 Chiller be lifted; exercise care to prevent the load
from becoming off-centred.
Caution!
The P030 Chiller can be moved with a lift truck with the forks being inserted under the load beneath
the recesses, from the broadside, symmetrically to the centre of gravity.
Transport Using a Lift Truck
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TRANSPORT AND STORAGE ENGLISH Translation of the Original
4.4 Transport Using a Crane

For the transport of the P030 Chiller, lifting eyes are provided in the upper frame enabling a 4-leg
sling load arrangement.
Load suspension devices

Wire rope slings (lifting rope assemblies) according to DIN 3088, or sling chains (lifting chain
assemblies) according to DIN 5687/ 5688. Both load suspending devices comply with the
requirement of a sling with equal rope or chain lengths to be used.
Rope inclination angle

Ensure that the rope inclination angle as shown in the illustration is complied with.
Lifting rate
Keep lifting rate to a minimum (VLift <10m/min – precision lifting, jerk-free lifting operation)
Depositing the P030 Chiller

To prevent any distortions of the lower frame from occurring, the P030 Chiller must be lowered onto
a level surface.
Transport Using a Crane
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4.5 Storage of the P030 Chiller

The P030 Chiller must be stored on a level surface, or supported on additional square beams, in a
dry room, protected from frost. Permissible storage temperature range: −20°C to 60°C.
For storage in ambient temperatures below 0°C, it i s imperative that decommissioning measures be
taken. (See Chapter Decommissioning)
Caution!
• It is, on principle, not allowed to stack the appliances. Stacking may lead to
serious accidents and damage to the units.
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INSTALLATION ENGLISH Translation of the Original
5 INSTALLATION
Caution!
• The safety notices contained in Chapter 1 must be complied with!
• In low storage temperatures (< 10 °C) allow for an appropriate acclimatisation

period before turning the unit on!
• Transport packaging to be removed before turning the unit on!
Installation of the P030 Chiller

The P030 Chiller is to be installed outdoors on a level, horizontal surface with adequate load
bearing capability.
Any attachments to the floor, intermediate spacers or anti-vibration mountings are not required. Any
national or local installation and mounting regulations must be complied with!
For different installation conditions, consult the manufacturer.
Notice!
• To ensure trouble-free operation of the P030 Chiller as well as to provide

adequate access for the performance of maintenance and repair work, minimum
clearances must be maintained when installing the unit. (See also Dimensions)
• These installation requirements ensure that the cooling air can be drawn in and
discharged without obstructions. It can thus be largely prevented that the air
discharged in upward direction is reintroduced into the chiller (air short-
circuiting).
• Moreover, adequate air changes for heat dissipation at the installation site must
be ensured.
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Translation of the Original ENGLISH MOUNTING
6 MOUNTING
Caution!
6.1 Connection of Water Piping

The hydraulic connections are located at the bottom on the left side of the unit The nominal pipe
widths and fitting connections are intended for use of the original hose set and/or the "Active hose
set".
In the case of differing connection conditions, all applicable technical data have to be submitted to
Glen Dimplex Deutschland GmbH in order to obtain from them a written special approval prior to
commissioning. To avoid any damage, the corrosion behaviour of the materials (used in the
equipment to be cooled) with respect to the water must be taken into consideration (see also the
Chapter Commissioning).
Connection of Water Piping
Notice!
• Where the piping system is installed at the installation site by the customer, care
must be taken that the pipe system is free from contamination (lines may have to
be flushed prior to connecting the P030 Chiller).
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MOUNTING ENGLISH Translation of the Original
6.2 Electro-Technical Connection

Activities to be performed:
− Open, disengage and remove panel assembly on the operating side using the supplied key
− Open the control cabinet door using the supplied key.
− Working from below, pass the connecting cable through the cable bushing provided in the base
plate
− Route cable properly inside the P030 Chiller and insert it in the control cabinet by passing it
through the screwed cable gland
− Establish electro-technical connection in accordance with the circuit diagram (see Appendix)
− The P030 Chiller is ready for connection to a remote control unit. In the delivery state a jumper
wire is inserted across the terminals. The general fault indicator is wired to the terminal in the
form of a potential-free contact. (See also circuit diagram in the Appendix).
− Close and lock the control cabinet door.
− Engage and lock the panel assembly.
6.3 Optical Fibre Connection

Activities to be performed:
− Open, disengage and remove panel assembly on the operating side using the supplied key.
− Working from below, pass the optical fibre cable through the cable bushing provided in the base
plate, route it properly and insert it in the control cabinet by passing it through the screwed
cable gland.
− Establish the connection in accordance with the enclosed installation instructions.
− Remove mating optical fibre component for the COO from the control cabinet and install it in the
COO.
− Install panel assembly, close the control cabinet door and lock both using the supplied key.
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Translation of the Original ENGLISH MOUNTING
Installation instructions for optical fibre cable
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COMMISSIONING ENGLISH Translation of the Original
7 COMMISSIONING
Caution!
• The P030 Chiller is designed exclusively for the cooling of water. Only liquids
complying with the specification may be used for filling the water circuits!
7.1 Water Circuit
7.1.1 Water Requirements

Only water of drinking water quality, at a minimum, see drinking water properties (page 8) – or a
water-glycol mixture in a ratio of 60:40% may be used.
The following materials may be installed in the water circuit of the P030 Chiller:
− Copper
− Stainless steel
− Brass
− Red bronze
− Plastic
Depending on the materials used in the chiller-remote water circuit (installation to be provided by
the customer) material incompatibilities could result in a corrosion hazard. This must especially be
taken into account where galvanised and aluminium materials are used. If in doubt, consult
competent specialist contractors.
7.1.2 Flushing, Filling and Venting
Notice!
• Due to the fact that the P030 Chiller and its downstream equipment to be cooled
can be installed at different levels, it must be ensured that the system is properly
filled and vented.
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Translation of the Original ENGLISH COMMISSIONING
6
1
2
5
3 7
Step Action
Connect the Filler device to the K-F-E valve [3] at the pump. Use a transparent hose for connecting it to
01 the K-F-E valve [4]. Put the open end of that hose into a pan or canister.
ATTENTION: Do not drain Glycol or Glycol mixtures into the sewage drain!
02 Open only the K-F-E valve [3] at the pump, all others have to be closed.
03 Close the ballvalves in the main branch [1 & 2].
04 Switch on the Filler device air bleeder [6] on the tank [5] is venting.
05 After finishing the venting process, open valve [2] and also K-F-E valve [4].
After escaping only pure cooling medium (without air bubbles) out of K-F-E valve [4], close this valve
06
and open ball valve [1].
Fill the cooling circuit up to a pressure of about 1.7 to 2bar (see pressure gauge [8]). While you´re doing
07
this, air bleeder [7] is venting.
After venting is finished, close K-F-E valve [3] at the pump. The pressure shown at the pressure gauge
[8] should stay stable for at least 10 minutes. If the pressure reduces, start again at step 05 and repeat
08 as long as the pressure is stable.
ATTENTION: Check the system for leakage at this step!
454522.68.07-01-E 29
27.06.2012
COMMISSIONING ENGLISH Translation of the Original
7.2 Initial Start-Up of the Pump

Danger!
• Always disconnect the power supply before working on the P030 Chiller.
• All control switches, motor protecting switches and automatic circuit breakers
must be placed to the "0" position!
The pump motor is equipped with a rotation direction sensor whose position can be changed.
Notice!
• A functional check of the rotation direction sensor should be carried out
before the initial start-up of the pump motor
whenever the position of the rotation direction sensor has been changed.
The functional check can be carried out by moving the rotation direction sensor, e.g. with your
finger.
To determine the direction of rotation of the pump motor, proceed as follows:
− Complete the procedure "flushing, filling and venting" as described in Chapter 7.1.2.
− Establish the electrical connections in accordance with Chapters 6.2 and 6.3.
− Switch on the pump.
− Observe the small display window in the rotation direction sensor.
The rotation direction is correct if a black area appears in the window, no further activities are
required.
In the event that a white area appears in the window, the following steps must be performed:
− Disconnect the P030 Chiller from the power supply, place all switches and automatic circuit
breakers to the "0" position.
− Reverse any two of the three electrical leads (phases).
− Re-check the rotation direction of the pump motor, as described above.
7.3 Refrigeration Circuit

After the activities on the water circuit and the pump have been completed, place the motor
protecting switches of the compressors to the -1- position (see circuit diagram in the Appendix).
Clear all pending fault messages at the control and operating unit. The P030 Chiller is ready for
operation and the control and operating unit takes over the control of the water outlet temperature.
Notice!
• Check the setpoint adjustment and change the setting, if necessary.
30 454522.68.07-01-E
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Translation of the Original ENGLISH DECOMMISSIONING
8 DECOMMISSIONING
Caution!
If the P030 Chiller is not used for an extended period or if it is to be disassembled, the unit has to
be taken out of service.
The following procedure should be followed:
− Control switch (at the front of the unit) in position "0"
− Main switch (at the front of the unit) in position "0"
− Switch off the power to the chiller
− Completely drain the water circuit, including tank, pump, pipes and filters (see flow diagram in
the Appendix).
Notice!
• Take freeze protection measures (consult manufacturer)
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SHUTDOWN IN EMERGENCIES ENGLISH Translation of the Original
9 SHUTDOWN IN EMERGENCIES
Danger!
− Turn power disconnect switch (main switch) on the control cabinet of the P030 Chiller to the
"OFF" position − „0“ −.
Main switch in "0" position
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Translation of the Original ENGLISH ENVIRONMENTAL REQUIREMENTS
10 ENVIRONMENTAL REQUIREMENTS
When repairing or placing the P030 Chiller out of service (decommissioning), the environment-
relevant requirements regarding recovery, reuse and disposal of fuels/oils and components
according to DIN EN 378 are to be complied with.
Notice!
• The operator of the P030 Chiller is responsible for the proper disposal of used
fuels, oils and system components.
The disposal of the water containing additives is to be effected in agreement with the competent
local authorities.
454522.68.07-01-E 33
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OPERATION OF CONTROL AND OPERATING UNIT ENGLISH Translation of the Original
11 OPERATION OF CONTROL AND OPERATING UNIT

The P030 Chiller is switched on by means of power disconnect switch (main switch) which also
doubles as an EMERGENCY STOP switch. The P030 Chiller is now ready for operation, and
control and operating unit takes over the control of the water outlet temperature. It is not possible to
start up the unit for as long as there is an active low water level or dry run protection signal.
11.1 Control and Operating Unit ST 181
No. Function No. Function

1 Display 7 SET call-up of setpoint
2 Alarm status displays S1 (compressor control)
General fault alarm S2 (not used)
Temperature alarm
Low water level
Pump 9 HP/LP button
Refrigeration fault Reading of HP sensor -> HP/LP button
High pressure HP pressed
Low pressure LP Reading of LP sensor -> HP/LP +
3 Control modes DOWN button pressed
1 Control setting 1 On 10 No function
2 Control setting 2 On
3 Control setting 3 On
4 UP button
to increase setpoint or parameter value
5 DOWN button
to decrease setpoint or parameter value
6 Buzzer button 11 No function
Press 1x: buzzer off
Press 2x: alarm reset
Control and Operating Unit ST 181
Actual values
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Translation of the Original ENGLISH OPERATION OF CONTROL AND OPERATING UNIT
In the normal state, the flow temperature of the water circuit is indicated on the display.
Setpoint adjustment
The setpoint is adjusted by simultaneously pressing the SET button and the UP or DOWN button.
454522.68.07-01-E 35
27.06.2012
MAINTENANCE ENGLISH Translation of the Original
12 MAINTENANCE
Caution!
• Always disconnect the the P030 Chiller from the power supply before attempting
to open the cabinet!
No specific refrigeration technology knowledge is required for the performance of maintenance

activities. This work can be carried out by a properly trained person with appropriate know-how.
Component to be Interval Activity

serviced
P030 Chiller 2 weeks - Visual inspection of the air
in general filter element for contamina-
tion
- Visual inspection of
refrigeration circuit for leaks
- In the case of oil leaks call
customer service:
Phone:+49 (0) 9221 / 709-545
Fax: +49 (0) 9221 / 709-529
Water circuit 2 weeks - Visual inspection of the water
cooling water circuit for leaks
- Check water level, top up
- Observe filling pressure
(pressure gauge and
diaphragm expansion vessel)
- Check water quality
Cooling air circuit 1 week Replace or clean filter element
Filter element Clean condenser with com-
Condenser pressed air, do not damage
fins
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Translation of the Original ENGLISH MAINTENANCE
12.1 Replacing Filter Element

The filter element can be replaced without any tools. Proceed as follows:
− Pull at the lower edge of the protective grille until it can be removed from the magnetic fixing
points.
− Disengage the protective grille at the top.
− Remove the filter element fixed in place by velcro fastener.
− The installation of a new filter element is performed in the reverse order of sequence.
View of the chiller from the left as well as a detailed view with protective grille and filter element removed.
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27.06.2012
PERIODICAL INSPECTIONS AND TESTS ENGLISH Translation of the Original
13 PERIODICAL INSPECTIONS AND TESTS
Caution
• Always disconnect the P030 Chiller from the power supply before attempting to
open the cabinet!
During the lifetime of the P030 Chiller, inspections and tests (not included in the scope of the
warranty) must be carried out in accordance with national regulations! If there are no local
regulations relating to periodical inspections, regular device-specific tests have to be performed
based on EN 378-2.
Scope of tests
Test Monitoring Test
designation
Visual Pressure test Refrigerant Function
inspection leak detection HP pressostat
M1 X X X X
M2 X X X
M3 X X
1)
M4 X X X
Monitoring and testing must be carried out by competent personnel (in accordance with
EN13313) or a specialist enterprise in compliance with environmental requirements with respect to
the reuse and disposal of fuels/oils and component parts.
Definition of Test Designations
M1 Inspections/tests must be carried out following any intervention in the refrigeration

circuit due to required repair or service activities (replacement of components,
elimination of leaks, replacement of filter-drier cartridges).
M2 Inspections/tests must be carried out prior to recommissioning a P030 Chiller following
an extended shutdown period.
M3 Inspections/tests must be carried out whenever – after the initial startup of the P030
Chiller at the end user's site – the unit is moved to a new location. Due to special
transport safety measures, any relocation of the P030 Chiller from the manufacturer's
plant to the end user does not statistically result in any increased failure rate and
therefore requires no re-inspection to be carried.
M4 A refrigerant charge of 11 kg requires a periodical check to be carried out once a year.
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Translation of the Original ENGLISH PERIODICAL INSPECTIONS AND TESTS
The visual inspection comprises the following:

− Inspection of the air filter elements on the condenser for cleanliness
− Inspection of the seal of the expansion valve
− Visual inspection of the refrigeration circuit for oil leaks in the area of the compressor and
condenser connecting lines (suction line, pressure line)
− Inspection of the condenser heat exchanger surface and the refrigerant piping for corrosion
damage
− Inspection of the mounting and attachment of all piping and components for security
− Visual inspection of the water circuits under operating conditions for leaks
− Check that the operating manual is available at the P030 Chiller
Notice!
• All periodical inspections and tests must be documented in the system logbook.
454522.68.07-01-E 39
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MALFUNCTIONS / TROUBLESHOOTING ENGLISH Translation of the Original
14 MALFUNCTIONS / TROUBLESHOOTING
Caution!
The basis for troubleshooting are the circuit diagram, the flow diagram and the messages displayed
on the control panel. The controlled variable is the main setpoint.
Displays on the Control and Operating Unit
See Chapter Operation of the Control and Operating Unit.
14.1 Malfunctions / Troubleshooting of Control and Operating Unit ST 181

Fault display in the event of a malfunction:
F1 -F23 will flash in alternation with the display of the actual value.
Acknowledging/resetting alarm messages on the control panel

After the fault has been eliminated, reset this alarm message by pressing the (buzzer) button:
− Press 1x (buzzer off)
− Press 2x (buzzer and fault RESET)
Fault Display Malfunction / Cause Remedy
F1 Motor fault, pump
Motor protecting switch has tripped
- Pump motor overloading due to Check pump, replace if necessary
mechanical sluggishness Place motor protecting switch in
position-1-
F2 Motor fault, compressor
Motor protecting switch has tripped
- Compressor motor overloading due Check compressor, replace if
to mechanical sluggishness necessary. Place motor protecting
switch in position -1-
- Motor overloading due to phase Correct phase failure. Place motor
failure protecting switch in position -1-
F3 Motor fault, condenser fan
Motor protecting switch or thermal contact
has tripped
- Fan motor overloading due to mechanical Check fan, replace if necessary. Place
sluggishness motor protecting switch in position -1-
- Motor overloading due to phase failure Correct phase failure. Place motor
protecting switch in position -1-
- Thermal contact of a fan has tripped, Check thermal contact for continuity,
motor winding overheated allow motor to cool, replace if necessary;
move motor protecting switch in position -
1-
40 454522.68.07-01-E
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Translation of the Original ENGLISH MALFUNCTIONS / TROUBLESHOOTING
F4 Fault due to high pressure

- High-pressure pressostat has tripped
- Cooling air temperature too high Ensure proper heat dissipation by
increased air changes at the
installation site
- Fans fail to rotate - Check fans for proper operation
- Condenser or filter element dirty Clean condenser with compressed
air (do not damage fins) or replace
filter element
- Water temperature too high Drain water and replace with fresh
water
- Load consumption too high Reduce load consumption or shut off
After a malfunction due to
excessively high pressure, the
pressostat must be reset manually
so that the P030 Chiller can be
restarted. The compressors and
fans will be enabled after a delay
of 180 seconds.
F5 Fault due to high-pressure limiter Ensure proper heat dissipation by
- Sensor has tripped increased air changes at the
- Cooling air temperature too high installation site
- Fans fail to rotate Check fans for proper operation
- Condenser or filter element dirty Clean condenser with compressed
air (do not damage fins) or replace
filter element
- Water temperature too high Drain water and replace with fresh
water
- Load consumption too high Reduce load consumption or shut off
- Panel assemblies not mounted on Mount panel assemblies
unit
After a malfunction due to
excessively high pressure, the
pressure limiter must be reset
manually so that the P030 Chiller
can be restarted. The compressors
and fans will be enabled after a
delay of 180 seconds.
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MALFUNCTIONS / TROUBLESHOOTING ENGLISH Translation of the Original

F6 Fault due to low pressure
- Ambient temperature too low Increase ambient temperature
- Water temperature too low Increase water temperature
- Water volume too low Clean filter, replace if necessary
Filter dirty Check shut-off valve
Shut-off valve closed
- Sensor has tripped The elimination of malfunctions in the
Refrigerant shortage due to leaks in refrigeration cycle may only be
refrigeration circuit performed by qualified personnel !
- Refrigerant shortage
- Expansion valve defective
- Permanent formation of bubbles in Call customer service!
sight glass
After the cause of the low-
pressure fault has been
eliminated, the alarm is
automatically reset.
The compressors and fans are
enabled after a delay of 180 sec.
F7 Low-pressure limiter The elimination of malfunctions in the
- Sensor has tripped refrigeration cycle may only be
Refrigerant shortage due to leaks in performed by qualified personnel !
refrigeration circuit
- Refrigerant shortage
- Expansion valve defective
- Permanent formation of bubbles in Call customer service!
sight glass
After the cause of the low-
pressure fault has been
eliminated, the alarm is
automatically reset.
The compressors and fans are
enabled after a delay of 180 sec.
F8 Condenser air filter dirty Replace condenser air filter
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Translation of the Original ENGLISH MALFUNCTIONS / TROUBLESHOOTING

F10 Fault message
Digital Fault input E7 Check filling pressure
F11 Flow control switch has tripped

- Leaks in water circuit Check water circuit for leaks, top up
water up to the MAX. mark
- Pump defective Check pump, replace if necessary
Move motor protecting switch to
position 1-
- Flow control switch defective Check flow control switch, replace if
necessary
- Shut-off valve closed Check all shut-off valves
- Water pressure too low Increase water pressure
F12 Temperature alarm
Sensor F4 Temperature limit values exceeded Allow water to cool. or replace
- Water temperature too high sensor, correct/reset any additional
malfunctions that may be signalled
F13 Temperature alarm

Sensor F4 Temperature limit values exceeded Increase water temperature,
- Water temperature too low correct/reset any additional
malfunctions that may be signalled
F19 Broken sensor or short circuit

Sensor F2
- Defective sensor Check sensor, replace if necessary

Sensor F3 Check sensor, replace if necessary
- Defective sensor

Fühler F4
- Defective sensor Check sensor, replace if necessary
F23 Eeprom error Any error in this memory is indicated

During operation, parameters are by a general fault alarm. Although the
permanently checked in the controller controller continues to operate, it
for consistency. must be replaced without delay.
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OPTIONS ENGLISH Translation of the Original
15 OPTIONS
15.1 Water Circuit
Strainer
The strainer is included in the hose set and fitted outside the chiller in the water inlet line.
Temperature sensor
The temperature sensor detects the water inlet temperature which is displayed at the control and
operating unit.
Temperature limit values

The water temperatures in the water circuit are monitored by limit values. If the preset limit values
are exceeded or not reached, a general fault alarm is issued on the control panel.
Flow control switch

The flow control switch is fitted in the water inlet pipe and is designed to monitor the flow rate in the
water circuit. If the minimum flow rate is fallen short of, the pump is switched off.
15.2 Electrical System

Glass fibre cable
A 100m long glass fibre cable is available as an option. As standard the P030 Chiller communicates
with the COO via a glass fibre cable up to 50m in length.
Control cabinet heater

The control cabinet heater is installed for temperature stabilisation of the control cabinet inside
temperature versus the ambient temperature (condensation water formation) and for the purpose of
ensuring minimum temperatures for the switchgear and controlgear inside the control cabinet.
Outdoor installation and pump shutdown upon a general fault alarm

In the event of a general fault alarm, the pump is shut down by the controller. After the fault has
been eliminated and a Reset carried out at the controller, the pump is restarted. If the general fault
alarm was triggered by the preset temperature limit value causing the pump to be shut down it is
necessary to carry out a restart. The restart is effected after the „fault reset“ has been carried out by
means of the ON/OFF control switch. The limit value alarm will be suppressed for 30 min. The
pump starts operating and the water temperature can drop below the preset limit value.
15.3 Cooling Air Supply

Protective condenser grille with air filter element monitoring
The max. permissible degree of contamination of the air filter element is monitored by the
condensation pressure.. If the max. permissible pressure is exceeded, a warning message "Filter
contaminated" is displayed on the control and operating unit.
44 454522.68.07-01-E
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Glen Dimplex Deutschland GmbH

HEADQUARTERS GERMANY NORTH AMERICA

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12.1 REPLACING FILTER ELEMENT .......................................................................................................................... 37

1 FOR YOUR SAFETY

1.2 Signs and Symbols

1.3 Safety Notices

• All relevant accident prevention regulations have to be observed.

• The safety devices must not be deactivated.

• The electrotechnical connections of the P030 Chiller must be performed

• Anyone working on the refrigeration circuit must be protected by personal

Drinking Water Properties

1.4 Handling of Refrigerants

1.5 Safety Requirements

(See Sample Quick Reference Guide)

1.5.3 Periodical Inspections/Tests

• The operator of the unit is responsible for the performance of periodical

1.6 Purpose of the P030 Chiller

• No changes are allowed to be made to the P030 Chiller.

1.7 Declaration of Conformity

2 DESCRIPTION OF THE P030 CHILLER

2.1 Overview P030 Chiller

View of an open chiller

2.2 Refrigeration Circuit

Block flow diagram, Refrigeration Circuit

2.3 Water Circuit

2.4 Cooling Air Supply

2.5 Safety Devices

High-pressure control (HP)

Power disconnect switch (main switch)

2.6 Monitoring Devices

Compressor overheat protection

Thermal contact – fan motor

Circuit breakers (compressor, fan, pump)

Flow and pressure switches in the water circuit

Control and operating unit

2.7 Electrical/Control Equipment

3.2 Electrical Data

3.3 General Data

3.4 Name Plate

3.4.1 Installation Location of the Type Plate

Location of the name plate and the barcode identification label

4 TRANSPORT AND STORAGE

• Damaged units must be sorted out immediately!

4.1 Transport Specification

4.2 Transport Using a Forklift

• The lifting rate should be kept to a minimum!

Recesses, Transport with Forklift

4.3 Transport Using a Lift Truck

• The lifting rate should be kept to a minimum!

Handling the unit from the broadside:

• The lifting rate should be kept to a minimum!

Transport Using a Lift Truck

4.4 Transport Using a Crane

Load suspension devices

Rope inclination angle

Depositing the P030 Chiller

Transport Using a Crane

4.5 Storage of the P030 Chiller

• The safety notices contained in Chapter 1 must be complied with!

• In low storage temperatures (< 10 °C) allow for an appropriate acclimatisation