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DeLaval compact water chiller CWC120 Instruction Book
© DeLaval 2012. 2012-10-11, Version 1
86827601 Original instruction
DeLaval compact water chiller CWC120 Table of contents EC Declaration of Conformity - DeLaval compact water chiller CWC120...................................... 5 Safety precautions.............................................................................................................................. 7 n DeLaval compact water chiller CWC60 n DeLaval compact water chiller CWC90 n DeLaval compact water chiller CWC120 1 2 3
4 5 6 7
Foreword........................................................................................................................... 7 Disclaimer......................................................................................................................... 7 Safety regulations............................................................................................................. 7 3.1 General............................................................................................................. 8 3.2 Installation and maintenance.......................................................................... 11 3.3 Notes on refrigerants...................................................................................... 12 Warranty.......................................................................................................................... 12 Safety labels on the equipment....................................................................................... 13 Type plate....................................................................................................................... 13 Transportation................................................................................................................. 13
General description........................................................................................................................... 14 n DeLaval compact water chiller CWC60 n DeLaval compact water chiller CWC90 n DeLaval compact water chiller CWC120 1 2 3
Introduction..................................................................................................................... 14 Main Features................................................................................................................. 16 Overview......................................................................................................................... 17
Planning.............................................................................................................................................. 19 n DeLaval compact water chiller CWC60 n DeLaval compact water chiller CWC120 n DeLaval compact water chiller CWC90 1
2
General recommendation................................................................................................ 1.1 Farm condition................................................................................................ 1.2 Regulations..................................................................................................... Positioning the units........................................................................................................ 2.1 Water chiller.................................................................................................... 2.2 Plate cooler..................................................................................................... 2.3 Additional components....................................................................................
19 19 20 20 20 22 22
Product data....................................................................................................................................... 23 n DeLaval compact water chiller CWC60 n DeLaval compact water chiller CWC90 n DeLaval compact water chiller CWC120 1 2
Article number:................................................................................................................ Technical Data................................................................................................................ 2.1 General........................................................................................................... 2.2 Requirements.................................................................................................. 2.3 Dimensions.....................................................................................................
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DeLaval compact water chiller CWC120 Table of contents Function.............................................................................................................................................. 26 n DeLaval compact water chiller CWC60 n DeLaval compact water chiller CWC90 n DeLaval compact water chiller CWC120 1 2 3
Water chiller.................................................................................................................... 26 Control box...................................................................................................................... 27 User interface.................................................................................................................. 29
Installation.......................................................................................................................................... 34 n DeLaval compact water chiller CWC60 n DeLaval compact water chiller CWC90 n DeLaval compact water chiller CWC120 1 2 3 4
5 6
Before installation............................................................................................................ Placing the unit................................................................................................................ Piping for water/glycol solution ....................................................................................... Electrical installation........................................................................................................ 4.1 Safety of electrical connection........................................................................ 4.2 Voltage range.................................................................................................. Fill the water chiller with water / glycol............................................................................ Connect heat recovery....................................................................................................
34 35 36 36 36 37 38 38
Start up............................................................................................................................................... 40 n DeLaval compact water chiller CWC60 n DeLaval compact water chiller CWC90 n DeLaval compact water chiller CWC120 1
Start-up document........................................................................................................... 40
Operator's maintenance.................................................................................................................... 42 n DeLaval compact water chiller CWC60 n DeLaval compact water chiller CWC90 n DeLaval compact water chiller CWC120 1 2 3
General........................................................................................................................... 42 Daily procedures............................................................................................................. 42 Monthly procedures......................................................................................................... 46
Troubleshooting................................................................................................................................ 48 n DeLaval compact water chiller CWC60 n DeLaval compact water chiller CWC90 n DeLaval compact water chiller CWC120 1
Troubleshooting table...................................................................................................... 48
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EC Declaration of Conformity Name of product:
DeLaval compact water chiller CWC120
Report No.
80008601
The product complies with requirements of the following directives: Machinery directive - 2006/42/EC Pressure Equipment Directive 97/23/EC Electro magnetic compatibility directive - 2004/108/EC Low voltage directive - 2006/95/EC Harmonised standards which have been used: EN ISO 12100:2010 EN 60204-1:2006/A1:2009 Other technical standards and specifications used: Pressure Equipment Directive 97/23/EC are category II module A1 (notified body no 1433, URZAD DOZORU TECHNICZNEGO, ul. Szczesliwicka 34, 02-353 Warszawa) Tumba 2012-10-20
Contact:
Signed:
Name:
Jan-Ove Nilsson
Position:
Vice President
Department:
BA Capital Goods
Jerzy Stopa P.O. Box 39 SE 147 21 TUMBA Sweden
Name and address of manufacturer: PPH Cool Lipowa 10 05-123 Chotomów Poland
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DeLaval compact water chiller CWC120 Safety precautions Safety precautions DeLaval compact water chiller CWC60 DeLaval compact water chiller CWC90 DeLaval compact water chiller CWC120 This chapter is valid for the three models of DeLaval compact chiller. All pictures, however, refer to DeLaval compact water chiller CWC60.
1 Foreword It is your responsibility to see that any person involved with the use or operation of this equipment follows all safety and operational instructions. Under no circumstances should you allow this equipment to be used if the equipment is faulty or the operator does not completely understand the operation of the equipment. The instructions in this book are focussed on the water chiller. It is of critical importance that you also pay attention to the instructions for the other components in the cooling system, such as for the cooling tank and the plate cooler.
2 Disclaimer The information, instructions and parts listed are applicable and current on the date when issued. DeLaval reserves the right to make changes without notice.
3 Safety regulations Definitions of admonishments Admonishments are safety related warning messages. Admonishments provide important information that is intended to prevent incorrect or hazardous use of equipment, machinery or software, and support risk assessment. The following list defines the different types used in DeLaval documentation:
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DeLaval compact water chiller CWC120 Safety precautions Danger: Refers to imminent and severe risk. Failure to comply with instruction will result in serious injury or death. Warning: Refers to a potential but severe risk. Failure to comply with instruction could result in injury or death. Caution: Refers to a limited risk. Failure to comply with instruction could result in minor injury or product damage. Mandatory: Refers to an action or behaviour which is essential to safe and successful use of the equipment. Prohibited: Refers to an action or behaviour which is incompatible to safe and successful use of the equipment. Note! Is intended to draw attention to specific points of importance in the text. This symbol signals risk of injury. This symbol signals risk of electric shock.
3.1 General The instructions in this book are focussed on the water chiller. It is of critical importance that you also pay attention to the instructions for the other components in the cooling system, such as for the cooling tank and the plate cooler. This document contains important safety information. Read these instructions carefully before using any part of the system!
Warning! The system must only be operated by trained personnel. Make sure that children and unauthorised persons do not come into contact with the system.
Warning! Never use the equipment for any other purposes than the intended use.
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DeLaval compact water chiller CWC120 Safety precautions
Warning! Do not push objects beyond covers, shields or guards. Failure to comply can lead to injury or equipment damage.
Warning! Loose hanging clothes should not be used when being close to moving parts. Long hair should be protected.
Mandatory! In case of a refrigerant leakage, avoid eye contact and call certified service personnel immediately.
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Warning! The indicated parts of the equipment can be hot. Do not touch these parts of the equipment without wearing suitable protective gloves.
Fig. 1: Compressors and piping inside the compressor room might be hot.
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DeLaval compact water chiller CWC120 Safety precautions
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Caution! Some parts of the equipment can be hot even when the system is not running.
Fig. 2: The heater inside the control box might be hot. Note, on Models CWC90 and 120 the heater is placed to the left in the control box.
Prohibited! Do not step on the indicated areas due to the risk of injury. Avoid also placing heavy objects on this area as it can destroy the equipment.
Warning! Be careful when cleaning the fins. The condenser fins are thin plates that can be sharp!
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Mandatory! Always wear suitable ear protection when working in the same room as a running unit. Fig. 3: Do not step on the water chiller or any piping
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DeLaval compact water chiller CWC120 Safety precautions 3.2 Installation and maintenance
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Danger! Always disconnect the main power supply, and if present lock the main switch in off position, before performing any installation, inspection, adjustment, maintenance, or service on the equipment. Wait for all moving parts to stop and any capacitors to discharge.
Danger! Opening of the control boxes and work on the electrical equipment should only be done by authorized electricians.
Warning! The installation of the equipment must be carried out by authorized mechanics.
Warning! During soldering or brazing, be aware of the fire hazard!
Warning! Fire and burn risk. Mixing of oil and refrigerant are inflammable. All refrigerant needs to be removed before system is unsealed. Avoid working with open fire when refrigerant is in cooling system.
Caution! Never clean the equipment with a high pressure cleaner or any other jet of water. The equipment is sensitive and can be destroyed by the high pressure.
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DeLaval compact water chiller CWC120 Safety precautions
Caution! Do not change parameter settings without knowledge of their possible effect. Changing parameter settings can result in incorrect operation or damage to the equipment.
3.3 Notes on refrigerants n Because of the environmental risks concerning the refrigeration, all recommendations and regulations should be considered. n If the refrigerant must be removed from the system it must be pumped into a gas cylinder, or similar equipment used for storing refrigerant. The refrigerant must not be released out in the air. n Never use any other refrigerant than the one the system is designed for. The required refrigerant is stated on the chiller unit's type plate. n Only certified cooling technicians are approved to work with refrigerant. Always follow local safety and environment regulations when working with refrigerant.
4 Warranty Note! DeLaval will not take any responsibility for damage resulting from faulty installation, operation or for improper or inadequate care and maintenance.
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DeLaval compact water chiller CWC120 Safety precautions 5 Safety labels on the equipment Labels indicating hot surfaces are placed on the compressors in the compact chiller and on the heater inside the control box.
No.
Label
Explanation
1
Hot
Be aware that the compressor and the piping in the cooling system reach temperatures that can cause burning if touched. The system can be hot even when it is not running. Be aware that the heater placed in the control box might be hot.
2
Read this first
6 Type plate
A B C D E
NAME
TYPE
kW MANUFACT. YEAR
SERIAL No. OIL EMKARATE RL32-MAF-
dm³
F G H
REFRIGERANT R507 CHARGE kg
COMRESSORS
A
I J K L
FANS
A A
1433
NOMINAL CURRENT
PUMP MAX PRESSURE HIGH/LOW SIDE ELECTR.t INPUT
HP= /LP kW
bar IP V+N+P
Hz
229263
MANUFACTURED FOR DELAVAL BY PPH “COOL” UL LIPOWA 10, 05-123 CHOTOMOW. POLAND
Fig. 4
7 Transportation See section “Transportation” in chapter “Installation” in instruction book for DeLaval compact water chiller.
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DeLaval compact water chiller CWC120 General description General description DeLaval compact water chiller CWC60 DeLaval compact water chiller CWC90 DeLaval compact water chiller CWC120
1 Introduction
227804
This chapter is valid for the three models of DeLaval compact chiller. All pictures, however, refer to DeLaval compact water chiller CWC60.
All DeLaval compact water chillers are designed for cooling water, which is used for instant cooling of milk in farms with traditional milking systems as well as AMR and VMS systems. The Compact water chillers are available in three models - CWC60, CWC90 and CWC120
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DeLaval compact water chiller CWC120 General description System executions System with one water chiller and one double bank (or Ecombi) PHE The water chiller is working in a system together with a plate cooler (PHE) for instantly cooling the warm milk from the milking system (MS) to the target temperature, somewhere around 4°C before it enters the milk tank (MT)
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The milk is pumped from the milking system (MS) into the plate cooler (PHE) is cooled down in one step. The milk is cooled down with a water / glycol solution from the water chiller (WC). The milk is delivered at the target temperature (or close to) to the cooling tank (MT). A by-pass pipe must be mounted between the two cooling sections in the Ecombi plate cooler. System with two water chillers and one plate cooler The milk is pumped from the milking system (MS) into the plate cooler (PHE) is cooled down in two steps.
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In the first step the milk is cooled down with a water / glycol solution from the first water chiller (WC). If two units of different capacity are used, the smallest unit should be connected to the first section in the Ecombi plate cooler. In the second step the milk is cooled down further with a water / glycol solution from the second water chiller (WC). This configuration is energy efficient because the first water chiller works on higher evaporator temperature. The milk is delivered at the target temperature (or close to) to the cooling tank (MT). System with pre cooling, one water chiller and one plate cooler The milk can also be precooled with tap or well water before the water chiller cools down the milk. When the initial milk temperature is lower less cooling capacity is required from the water chiller.
228767
WC
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DeLaval compact water chiller CWC120 General description A smooth operator is needed to control the milk flow The milk flow is an important factor in an instant cooling solution. Chiller capacity required to cool the milk is directly related to milk flow. The flow from the water chiller cannot be adjusted. Therefore it is important to set milk flow to level matching installed chillers capacity or less. A smooth operator must therefore be used for controlling the flow from the milking system through the plate cooler. For more information see the Smooth Operator MEMO book 928053.
2 Main Features n DeLaval compact chiller is robustly designed with doubled major components (pumps, compressors, freon circuits). If a component breaks down at least part of capacity remains. n The compact unit is preset from factory and includes the control box, which makes the installation on farm easy. n Only glycol connections to PHE and electrical connections are needed on farm. n Standard water plastic pipes (with insulation) may be used for glycol connections. n The water chiller is possible to place outside the building. n The unit is prepared for heat recovery.
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DeLaval compact water chiller CWC120 General description 3 Overview Main components 1
1 2 3 4
Condenser Control box Heat exchanger for heat recovery Glycol container with overflow pipe
1 2 3 4
Connections for chilling and heat recovery Circulation pump Evaporator Compressor; (Model 60kW has two and models 90kW and 120kW have four compressors). Lifting point, (four in total)
4 3 227801
2
Fig. 5: CWC60
1
5
4
3
2
227802
5
Fig. 6: CWC60
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DeLaval compact water chiller CWC120 General description Control box
2
1 Compressor 2 RUN
Compressor 3 RUN
Compressor 4 RUN
General Alarm
Auto Mode
Manual Mode
STOP
3
Main switch Display LEDs and buttons
The parameters that control the function of the water chiller system can be accessed via the display on the control box. The temperature of the water/ glycol solution is shown in the display when the system is switched on.
227903
Compressor 1 RUN
1 2 3
Fig. 7
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DeLaval compact water chiller CWC120 Planning Planning DeLaval compact water chiller CWC60 DeLaval compact water chiller CWC120 DeLaval compact water chiller CWC90
1 General recommendation DeLaval compact chillers are designed for n Outdoor or indoor operation n Placing on the ground level or on a roof Recommendation: Place the Compact water chiller outside building with no roof above.
1.1 Farm condition n Make sure that the space intended for the chiller is big enough to accommodate the cooling equipment and possibly additional equipment like pre-cooling, heat recovery, reuse of cleaning water or a pipeline cleaner with sink etc. Note also the need of space for proper maintenance. n Make sure that the space will have adequate lighting. n Make sure that there is a proper power supply on the farm and that there is an exclusive power supply for the cooling system. n All measures must be taken to isolate the unit from the access of non-authorized people. Warning! The system must only be operated by trained personnel. Make sure that children and unauthorised persons do not come into contact with the system. Indoor placing: n Make sure that the size of the door is adequate for the cooling equipment to enter and exit. n Make sure that there is adequate ventilation. Consultation with a ventilation specialist is recommended. n Make sure that air circulates freely.
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DeLaval compact water chiller CWC120 Planning Outdoor placing: n Consider weather conditions (snow blocking etc). Placing on a roof n Consider lightning (thunderbolt) protection. Protection system has to be built around the compact chiller unit and connected to existing system for the building. (mast, spires etc. Follow the local standards and/or EN norm 62305 n Consider the proper strength of the base mounting. Consultation with the building contractor is recommended.
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n Consider that the centre of gravity for the unit is not in the middle. About 2/3 of the weight is assigned to the part where the compressors are placed. n In order to minimize the vibrations transmission the unit should be placed on the antivibration legs or rubber
Fig. 8
1.2 Regulations Always consider existing regulations: n Regulations about electrical power supply and requirements. n Regulations about water supply. n Regulations about refrigerants. n Regulations about draining waste water. n Regulations about LPS ( lightning protection system)
2 Positioning the units 2.1 Water chiller n The unit must be placed on a flat horizontal surface. n The load capacity must be matched to the total operation weight of the unit with all additional equipment.
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DeLaval compact water chiller CWC120 Planning n A concrete plate with foundations below the freezing level is recommended to use. This plate must not be connected with the building foundations in order to avoid the vibrations transmission. n When the unit is installed on an elevated platform the service access must be provided. Plan for minimum distances shown in Fig. 9 and Fig. 10. A B
min 1400mm min 1400mm (Service access to compressor room) C min 1400mm D min 500mm (out- and inlet connections)
B C
A
228608
D
Fig. 9
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DeLaval compact water chiller CWC120 Planning n A free space around the unit is needed in order to prevent recirculating air flow across the condenser coil. The distance between two neighbouring units cannot be less than 1400mm. n There should be a free entrance and exit of air around condenser. It is important to arrange a good air flow as the condenser is air cooled. n Avoid that air circulates through the unit. Air that has taken up warmth in the condenser should be ventilated out of the room directly. n For the optimal cooling efficiency we recommend that the condenser is placed near a fresh air inlet in the wall. The distance between wall and condenser should be about 2.5 - 3.0m.
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A
Fig. 10: A = 3m
2.2 Plate cooler
Y
The height (Y) between the in- /outlet on the water chiller and the in- /outlet on the plate cooler must not exceed 2 m.
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X
Keep the distance from the water chiller to the plate cooler as short as possible. Too great distance between the units (X+Y) might have a negative effect on the flow from the water chiller as the length of the piping, the number of bends, and the height distance between the water chiller have influence of the flow.
Fig. 11
2.3 Additional components Following additional components are needed for instant cooling: n Smooth operator For more information see the Smooth Operator Memo book 928053.
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DeLaval compact water chiller CWC120 Product data Product data DeLaval compact water chiller CWC60 DeLaval compact water chiller CWC90 DeLaval compact water chiller CWC120 This chapter is valid for the three models of DeLaval compact chiller. All pictures, however, refer to DeLaval compact water chiller CWC60.
1 Article number: 3x400V 50Hz
60kW
86127980
90kW
86128080
120kW
86358680
227800
DeLaval Compact Chiller
Fig. 12
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DeLaval compact water chiller CWC120 Product data 2 Technical Data 2.1 General DeLaval Compact Chiller 60
DeLaval Compact Chiller 90
DeLaval Compact Chiller 120
Capacity at 32 ºC :
61,6 kW
92 kW
122
Capacity at 38 ºC :
60kW
88kW
118kW
Compressors:
2x Emerson ZB114
4x Emerson ZB76
4 x Emerson ZB114
Capacity control:
50%/ 100%
25%/ 50%/ 75%/ 100%
Connection:
2”
2,5”
Circulation pump:
2x Ebara 10
Cooling circuits:
2 with expansion valves
Evaporator type:
Plate Copper Brazed
Glycol:
propylene 39%
Refrigerant:
R507 factory charged and tested
Controller:
Eliwell
Heat recovery:
CB included
Noise level, when all fans are working
82 dB at 1 m distance
m3/h
2x Ebara 15 m3/h
Note! Enough spare glycol should be kept at site to refill the installation in case of leakage. Article Number: 830762455 Glycol, 55 gallon/ 200 L Article Number: 4783200271 Anti freeze Propylene-Glycol, 25 kg
2.2 Requirements Electrical supply: 3 x 400 V, 50Hz.
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DeLaval compact water chiller CWC120 Product data 2.3 Dimensions
H
L
227803
W
Fig. 13
DeLaval compact L=length (mm) chiller
W=width (mm)
H=Height (mm)
Net weight (kg)
60kW
2650
1700
1900
900
90kW
2900
2250
1900
1500
120kW
3000
2250
1900
1700
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DeLaval compact water chiller CWC120 Function Function DeLaval compact water chiller CWC60 DeLaval compact water chiller CWC90 DeLaval compact water chiller CWC120 This chapter is valid for the three models of DeLaval compact chiller. Most pictures, however, refer to DeLaval compact water chiller CWC60.
1 Water chiller
9
When a signal is received from the milking system, or when manual mode is selected, the internal circulation pumps (3) start to circulate the water / glycol solution from the glycol tank (2) through outlet (7) to the external plate cooler (BM or M6 Delaval Plate Cooler) to cool down the milk.
10
The temperature of the water/glycol solution in the glycol tank (2) is kept at the set point, which is programmed in the controller. The set point should be set to 1- 2°C. Setting too low set point may lead to frozen milk and possible breakdown of plate heat exchanger. 1 8 2
3
5 4
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7 6
Fig. 14: Water chiller, seen from above
The water/ glycol solution returns from the plate cooler to the water chiller through inlet (6). When the temperature of the water/glycol solution rises above the set point controller starts compressors (1, 2) that compress the gas from the evaporator and press it through the condenser (3). In the condenser the gas is lead through copper tubes where it is cooled down by fans (4) blowing air through the condenser. The gas condensates back into liquid and flows into the evaporator via expansion valves. In the evaporator refrigerant evaporates taking heat from water/glycol and causing its temperature to drop. When the set point is reached, the compressors are stopped until a new batch of hot milk comes from milking system. Internal circulation pumps (1, 2) are always working and circulate the water/ glycol solution through the plate cooler to cool down the milk. Note! The water chiller is prepared for Heat Recovery system (HRS) by component 1. Heat exchanger and 4, 5 Pipe connections. Additional accessories are, however, required.
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DeLaval compact water chiller CWC120 Function 3 4
228615
2
1
Fig. 15: Compressor room and condenser
2 Control box All the protection and control devices are placed on the panel inside the liquid chiller casing. The system is controlled by Eliwell SD655/C/S unit. The controller is protected by an access password No password is, however, required for changing the basic parameters as set point, hysteresis of switching on/off the compressors. Any adjustments of the settings should be done by DeLaval service technician. Caution! Do not change parameter settings without knowledge of their possible effect. Changing parameter settings can result in incorrect operation or damage to the equipment.
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DeLaval compact water chiller CWC120 Function 1 2 3
2
1 Compressor 2 RUN
Compressor 3 RUN
Compressor 4 RUN
General Alarm
Auto Mode
Manual Mode
STOP
The main switch turns the system into the STAND-BY mode - liquid chiller is switched off. In STAND -BY mode it is possible to change the setting without danger of an accidental start-up of the unit. The main switch cuts-off the voltage in control box.
3
227903
Compressor 1 RUN
Main switch Display LEDs and buttons
Fig. 16 LEDs and buttons 1
2
3
Compressor 2 RUN
General Alarm
4
5
6
Auto Mode
Manual Mode
STOP
1 2 3 4 5 6
Compressor 1 RUN Compressor 2 RUN General alarm Auto Mode Manual Mode Stop
1 2 3 4 5 6 7 8
Compressor 1 RUN Compressor 2 RUN Compressor 3 RUN Compressor 4 RUN General alarm Auto Mode Manual Mode Stop
227945
Compressor 1 RUN
Fig. 17: CWC60, LEDs and buttons,
1
2
Compressor 1 RUN
Compressor 2 RUN
3
4
5
Compressor 4 RUN
General Alarm
6
7
8
Auto Mode
Manual Mode
STOP
Compressor 3 RUN
227946
The alarm diode includes all types of alarm. The reason for the alarm is found from the display. For more information see chapter Operators maintenance. Fig. 18: CWC90 and 120 LEDs and buttons
Pressing Manual Mode button activates cooling process. It is important to press Stop button before starting cleaning of the milking installation. Otherwise chiller will decrease cleaning solution temperature and seriously degrade cleaning performance. In Auto mode cooling and stand by functions are switched based on external signal from milking plant (e.g. C200).
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DeLaval compact water chiller CWC120 Function 3 User interface How to read the display The front panel of the device functions as the user interface and is used to perform all operations relating to the device. Note! Performing operations should only be done by a service technician. There are 4 keys on the front panel. Each key has:
227904
n a "direct" action (indicated on the key) n an "associated" function (indicated on the front panel of the device beside the key). In the manual, this is shown in square brackets (e.g. [UP]) n a "combined" action involving two keys. In the manual, this is shown in square brackets (e.g.[UP+DOWN]) Fig. 19: Display
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DeLaval compact water chiller CWC120 Function Description of keys and associated functions Key
Description
Single press (press and release)
UP
Increases a value
Key Prolonged press [associ- [press and hold for ated about 3 seconds] function]
Goes to the next label
[Manual defrost activation]
Functions menu see Functions chapter (folder FnC)
[Local ON/OFF]
See Local On/ OFF section
Modify Set Point (if UI25=1) DOWN
decreases a value Goes to the previous label
See also Functions menu Functions chapter (folder
Modify Set Point (if UI25=1) Esc(ape)
Menu / Comments*
Quit without saving new settings
Change-over]
See section on Changing operating mode
Main Display
[Main Display Menu]
go back to previous level Set Confirm
Confirms value / quit and save new settings Move to next level (open folder, subfolder, parameter, value) Open States Menu
ALL
Alarm acknowledgment
See Manual alarm acknowledgment and reset section
* For more information see the Eliwell instruction book.
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DeLaval compact water chiller CWC120 Function Descriptions of keys - combined action Symbol [function Key combination associated to combined operation of the keys]
Combined press Single press (press and release
[associated func- [Menu] / Comtion] ments*
UP + DOWN
[Manual reset]
See Manual alarm acknowledgment and reset section
Esc + Set
[Open Programming menu]
[Programming menu]
* For more information see the Eliwell instruction book.
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DeLaval compact water chiller CWC120 Function Description of the display icons Icon
Description
Colour
ON
Blinking
Alarm
Red
Alarm generated
Alarm acknowledged
Heating
Green
Heating mode
Antifreeze with heat pump Remote Heating mode
Cooling
Green
Cooling mode
Remote Cooling mode
Stand-by
Green
Local stand-by mode (from keyboard)
Remote stand-by
Defrost
Green
Defrost active
Manual defrost activated
Economy
Green
Configurable
Configurable
Clock (RTC)
Red
Shows current time Set time (24hr format) Program time Time bands enabands bled
Degrees centigrade
Red
/
/
Pressure (bar)
Red
/
/
Relative humidity
Red
Not used
Not used
Menu
Red
Navigation menu
/
Loads
Amber
Configurable
Configurable
Time bands
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DeLaval compact water chiller CWC120 Function Default configuration, LEDs for utilities are all configurable (see parameters chapter, folder Ui). The factory settings are listed in the table below: LED symbol on display LEDs
© DeLaval 2012. 2012-10-11, Version 1
default
LED 1 (first from left)
Power step 1
LED 2
Power step 2
LED 3
Power step 3
LED 4
Power step 4
LED 5
Internal exchanger electric heater 1
LED 6
External exchanger fan
LED 7
Internal circuit water pump
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default icon on front panel
86827601 Original instruction
DeLaval compact water chiller CWC120 Installation Installation DeLaval compact water chiller CWC60 DeLaval compact water chiller CWC90 DeLaval compact water chiller CWC120
1 Before installation Delivery The unit is completed when delivered; charged with refrigerant, with programmed controller. All measures must be taken in order to avoid any damages during manipulation. Confirm that the unit received is the one ordered and check if there are any transport damages. If any, make a note in the delivery letter and insist on the inspection with the forwarder. In order to avoid dust/debris to enter the installation do not remove the protections on the connections until the whole installation is ready to connect. Transportation
228611
Lift the unit only by using the designed lifting points. If the unit will be installed on the roof, prepare adequate slings. The unit can be transported also by truck or tractor. Read instructions about safe transportation in chapter Safety precautions.
Fig. 20
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DeLaval compact water chiller CWC120 Installation When transporting the unit with a fork lift: n Use fork lift capable of lifting at least 3 tons n Use forks of length at least 2000mm for CWC 60 and 2500mm for CWC 90/120 n Chillers may be lifted from side or from compressor compartment side.
229264
Note! Never lift chillers from pipe outlet side.
Fig. 21
2 Placing the unit DeLaval compact chillers are designed for outdoor operation on the ground level or on the roof. Check that the place and the foundation prepared for the compact water chiller are carried out according to the recommendations in the Planning chapter: n The surface should be flat and horizontal. n The load capacity must be matched to the total operation weight of the unit with all the additional equipment. n There must be a free air circulation. For roof installation: n The proper strength must be taken into account. In order to minimize the vibrations transmission the unit should be placed on the anti-vibration legs or rubber.
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DeLaval compact water chiller CWC120 Installation 3 Piping for water/glycol solution Connect piping for water/glycol solution after final unit placing. Follow the rules of proper piping installation in order to obtain the maximum cooling capacity. The piping must be clean and completed according to the design. Note that all the changes of flow direction bends create additional pressure losses. Remember about the shut-off valves for service. Piping connected directly to the unit connections must be elastic or equipped with anti-vibration components. Drain connections must be placed in the lowest points of installation. Air vent valves must be installed in the highest point of installation. Both drain and air vent valves must be placed outside of the insulation in order to be easily accessible. The following aspects must be taken under account: 1. Use the connection dimensions given in the unit specification (See chapter Product data). 2. Check that the connections are clean. 3. Before connecting to the liquid chiller the piping system must be flushed in order to remove all the impurities. Take care not to flush the impurities into evaporator. 4. Connect chiller outlet A with plate cooler inlet B and chiller inlet C with plate cooler outlet D. 5. Whole piping must be insulated to prevent water condensation on the outer surface.
C A B
228612
D
Fig. 22
4 Electrical installation 4.1 Safety of electrical connection Note! The electrical connection should be made according to local regulations. Always compare the mentioned recommendations to the local regulations.
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DeLaval compact water chiller CWC120 Installation The compact water chillers are supplied with a complete power supply/control panel ready to use. Note! Before the main power supply is connected to the system, the connections between the components in the system must be completed according to the description in this chapter and according to the wiring diagrams in the Diagram chapter. n Connect the power supply according to the instruction. Always run the cable near to the wall or in cable ducts.
19313
n Before opening the electric box cut off the power supply by the external switch. n Check the grounding system before start up. n Check all the electrical connection, external cables connection and the insulation of all the cables. n Replace cables with damaged insulation. n Do not use the unsuitable cables or temporary connections. Power supply cables must be connected to the terminals on the electric panel through the main switch protected by fuses, according to the IEC norms or local regulations. Minimum current load and maximum size of the protections is given in electric diagrams. When all electrical connections within the system are completed, the main power supply can be connected to the water chiller.
4.2 Voltage range Note! Operation outside the voltage range indicated below can cause serious damage of the unit.
Nominal parameters of power supply [V-Ph-Hz] 400-3-50
© DeLaval 2012. 2012-10-11, Version 1
Min. voltage
Max. voltage
[V]
[V]
362
440
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DeLaval compact water chiller CWC120 Installation 5 Fill the water chiller with water / glycol Note! Check the local regulation to make sure that the cooling medium you use is allowed for food processing. Note! Use propylene glycol to make the mixture. Article Number: 830762455 Glycol, 55 gallon/ 200 L Article Number: 4783200271 Anti freeze Propylene-Glycol, 25 kg n Double check that the unit is levelled.
A
n Remove the side panel. n Fill water / glycol solution in the glycol container. n Run circulation pumps for one minute. n Check the level and repeat the procedure if needed. – Recommended level (A) is when glycol is little below elbow on the pipe. – Low level (B) is on middle of the pipe.
228607
B
Fig. 23
6 Connect heat recovery The water chiller is equipped with heat exchanger for heat recovery and output to start circulation pump when one of the compressors is working. Indirect heat recovery, with glycol/water solution as heating media is advised. Delaval offers vessels with internal pipe heat exchanger in sizes of 500 l and 900 l.
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DeLaval compact water chiller CWC120 Installation Article numbers: 86792080
Storage tank HT500 + cover
86792180
Storage tank HRS900 + cover
4781101570
Circulation pump UP 25-60 RG
1. Build heat recovery loop between storage tank heat exchanger, chiller heat recovery heat exchanger and circulation pump with 1" or bigger pipes. Use small open expansion vessel (~10l) in the loop. 2. Isolate pipes to ensure minimal heat loss. 3. Fill the loop with glycol/water solution of freezing point -35°C or less. Make sure there is no air in the loop otherwise the pump will not operate properly. 4. Connect the pump electrical cable with output for pump control according to electrical diagram.
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DeLaval compact water chiller CWC120 Start up Start up DeLaval compact water chiller CWC60 DeLaval compact water chiller CWC90 DeLaval compact water chiller CWC120
1 Start-up document The Start-up document should be filled in by the service technician at Start-up. Note! Properly filed startup document will be needed in order to process any warranty claim.
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DeLaval compact water chiller CWC120 Start up Start up document Technician company:
Start up date:
Farm name: Farm address:
Chiller type: Serial number: Values of voltage: phase L1
V
phase L2
V
phase L3
V
Check the value of 24V voltage:
V
Set point Set point
°C
Control range (differential range)
°C
Operation parameters Glycol solution outlet temperature
°C
Glycol solution Inlet temperature
°C
Ambient temperature
°C
Suction pressure
bar
Discharge pressure
bar
Compressor 1, current
A
Compressor 2, current
A
Compressor 3, current (only CWC90 and 120)
A
Compressor 4, current (only CWC90 and 120)
A
Service technician
Customer representative
Signature:
Signature:
Name:
Name:
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DeLaval compact water chiller CWC120 Operator's maintenance Operator's maintenance DeLaval compact water chiller CWC60 DeLaval compact water chiller CWC90 DeLaval compact water chiller CWC120 This chapter is valid for the three models of DeLaval compact chiller. All pictures, however, refer to DeLaval compact water chiller CWC60.
1 General Regular maintenance has to be carried out to prolong the lifespan of the cooling system and to avoid expensive repairs. Carry out the check points according to the maintenance interval shown below.
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Danger! Always disconnect the electrical power supply and lock the safety switch before performing any inspection, adjustment or maintenance.
2 Daily procedures Check for alarms If the General alarm on the control box is lit, go to the alarm display and check the alarm. n Call a service technician and tell the alarm number and name.
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DeLaval compact water chiller CWC120 Operator's maintenance Alarm display
227904
Press the Set key from the main display
Fig. 24
227913
The label Ai will appear on the display. Use the UP and DOWN keys to browse the other labels until you find the AL label
Fig. 25
227914
Press the set key to view the label of the first active alarm (if it exists)
Fig. 26
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DeLaval compact water chiller CWC120 Operator's maintenance In this case, the first alarm is Er01. Use the UP and DOWN keys to scroll any other alarms. Note! The menu is not cyclical. For example, if the active alarms are Er01, Er02 and Er03, the display will show Er01->Er02 ->Er03
