Kemppi Mastercool 30, Service Manual

Page 1: ...Kemppi Oy SERVICE MANUAL Mastercool 30...

Page 2: ...d jumpers 8 3 6 Control card LEDs 8 4 SERVICE INSTRUCTIONS 9 4 1 Cooling liquid 9 4 2 Cooler maintenance 9 4 2 1 Detaching and fastening the pump 9 4 2 2 Fastening the Generation1 dual water hose to t...

Page 3: ...discharges the voltage while it is turned off but it is always better to ensure this by measuring the voltage Wait at least one minute for the capacitors to become discharged Different digital multime...

Page 4: ...d type is SPW006214 card number W004736 it has same control logic as Mastercool 20 Main idea compared to earlier cards is that motor has lower running speed and better ability to tolerate long water h...

Page 5: ...N 3 1 Technical data Mastercool 30 Operating voltage 24VDC Cooling power 1 0 kW Connection capacity 100 ED 50W Maximum pressure 4 0 bar 100 ED I eff 1 12 9 A Cooling liquid 20 40 glycol water Tank vol...

Page 6: ...rsion 1 0 1 11 2011 4 Kemppi Oy 3 3 Construction The cooling fan is installed so that the air flows from the left side plate to Z001 card Air comes out through the front and the back plate grills Left...

Page 7: ...Inner structure 1 Fastening points to power source 2 Hot water return snap connector red 3 Cool water output snap connector blue 4 Hydrocool pump 5 A001 control card 6 Water tank filling hose 7 Water...

Page 8: ...001 control card structure 1 Connector X5 not in use 2 Connector X7 Positive output for pump motor 3 Connector X8 Negative output for pump motor 4 Connector X4 PTC and cooling fan connector 5 Connecto...

Page 9: ...age and to protect water hoses Motor runs piston that moves the membrane Membrane develops pressure that is hold with two pressure valves Piston type movement has a vibration as a side effect and it m...

Page 10: ...ong water cables or cold temperature In these cases jumpers X11 and X10 can be used to get more tolerance to keep cooler running While coolant level is too low the only possibility is to add more of i...

Page 11: ...rm use Water tank and pump should be cleaned frequently Time frame depends on the used coolant and coolers working hours Ethanol keeps system more clear than glycol It is best to check in certain peri...

Page 12: ...and then the outer hose upon the inner hose Only then you can be sure to get the reliable fastening Use your index finger to support the pump nib to avoid bending it while tightening the hose clamp Be...

Page 13: ...surements and tests 4 3 1 Troubleshooting in error cases The next two chapters may give ideas how to rectify possible cooler error cases Before making further actions to cooler it is best to change an...

Page 14: ...o container if water flows circulation is ok Check that pump can raise the pressure while water hoses are connected See the next section Normal operational pressure 4 3 2 Operational tests During the...

Page 15: ...sure can be up to 4 bars If normal working pressure is near 1 bar there can be problem in pump membrane and or pressure valves See next pages to maintain the pump Water cooled gun adds approx 0 5 bars...

Page 16: ...ltage measuring gives basic information of possible problems Mastercool 30 requires 24 VDC for control electronics pump motor and cooling fan Input voltage from the power source 24VDC X3 3 Ground X1 3...

Page 17: ...rrent minimum limit alarm pressure low or no water Open alarm on Closer alarm off H1 Cooling liquid temperature too high H2 Pump motor current too low no water Alarm level can be adjusted by trimmer R...

Page 18: ...y cooler Closed PTC monitoring by power source X22 Pump motor current minimum alarm pressure low or no water Open alarm on Closed alarm off H1 Cooling liquid temperature too high H2 Pump motor current...

Page 19: ...Service manual Mastercool 30 Version 1 0 1 11 2011 17 Kemppi Oy Notes...

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