Hypertherm Koolant Koolers N-Series, User Manual

Page 1: ...Koolant Koolers N Series Plasma Cutter Chiller Original Instructions 800 968 5665 dimplexthermal com User Manual Hypertherm Inc Part Number 810540...

Page 2: ...l numbers These can be found on the data tag on the CHILLER or on the Datapack information that shipped with the unit Information Subject to Change While every effort has been made to ensure the accur...

Page 3: ...ke and Exhaust Clearance 14 5 2 6 Proximity to the Plasma Cutting System 15 6 Installation 15 6 1 Checking for Shipping Damage 15 6 2 Transportation 15 6 3 Unpacking from the Crate 16 6 4 Internal Acc...

Page 4: ...2 Viewing Active Alarms 30 8 2 3 Resetting Alarms 30 8 3 Main Menu 31 8 4 Chiller Status 31 8 5 Monitoring 33 8 6 Devices 36 8 7 Setpoints 40 8 8 Maintenance Service 41 9 Troubleshooting 44 9 1 Alarm...

Page 5: ...0 Logic 61 Electrical Panel 62 Electrical BOM 63 Appendix C Default Controller Settings 64 Program Settings 64 Sensor Calibration 65 Alarm Settings 66 I O Module 67 Appendix D Warranty 68 Warranty Cov...

Page 6: ...gure 20 Devices 36 Figure 21 Devices Compressor Status 36 Figure 22 Devices Process Pump Status 36 Figure 23 Devices Recirculation Pump Status 37 Figure 24 Devices Heater Status 37 Figure 25 Devices F...

Page 7: ...ctrical Supply Power Requirements 18 Table 6 Chiller Plumbing Connections 22 Table 7 Recommended Compressor Warm up Time 26 Table 8 Chiller Statuses 31 Table 9 Alarm List 44 Table 10 Manual Revisions...

Page 8: ...rcuit Number of Process Pumps 1 Process Pump Motor Power 1hp 0 75kW Nominal Process Pump Flow Rate 1 3GPM 4 92LPM Pressure Relief Valve Setting 190 230PSI 13 1 15 9bar Nominal Process Coolant Supply T...

Page 9: ...the OFF position does not isolate power from the unit The only way to isolate all power from the unit is to turn the chiller s main circuit breaker disconnect to its OFF position This should only be...

Page 10: ...t Tank Drain Emergency Stop Fluid Inlet Local Off Remote Fluid Outlet Tank Level High Tank Fill No Tap Water Refer to Manual Tank Level Low Electrical Shock Hazard Do Not Turn Off Lock Out Tag Out Ref...

Page 11: ...return coolant temperature from the plasma cutter prior to passing through the brazed plate heat exchanger Highly reliable no sliding components Variable speed condenser fan Minimizes acoustic noise I...

Page 12: ...MC M 5 Ton Plasma Cutter Chiller 69 800 Btu hr 20 5kW 802092 NVI 5001 NR CE MC M 5 Ton Plasma Cutter Chiller w o Refrigerant 69 800 Btu hr 20 5kW Rated capacity based on 59 F 15 C leaving fluid temper...

Page 13: ...troduction Rated Capacity 11 Figure 2 Plasma Cutter Chiller Plumbing I O Side PLUMBING I O INTERLOCK CONNECTIONS ETHERNET CONNECTIONS TANK DRAIN TANK LEVEL SIGHT GLASS Hypertherm Inc Part Number 81054...

Page 14: ...special applications that do not adhere to the requirements in the table below contact Glen Dimplex Thermal Solutions GDTS engineering for review Table 4 Chiller Operating Environmental Requirements C...

Page 15: ...talling overhead plumbing between the chiller and the plasma cutting system can cause the chiller fluid reservoir to overflow 5 2 3 Electrical Enclosure Clearance OSHA and the NEC both mandate a minim...

Page 16: ...feet of vertical clearance is required from the top of the exhaust fans to the building ceiling or any other obstructions that could impede exhaust air flow CAUTION Installing the chiller in a buildi...

Page 17: ...r filter s of the chiller Any damage must be reported to the shipping carrier and a copy of the damage claim submitted to GDTS or your sales representative 6 2 Transportation The chiller is shipped in...

Page 18: ...ternal bracing to the two long sides 5 Remove the 3 8 16 bolts securing the shipping brackets to the base of the chiller using a 9 16 wrench 6 Cut the shipping bag that the chiller was placed in 7 Cut...

Page 19: ...e Upper Blocker and pull outward to release the fingers at the top of the Upper Blocker from the machine sides and remove the Upper Blocker 4 Reinstall in the opposite order when access is no longer r...

Page 20: ...cal codes Table 5 Chiller Electrical Supply Power Requirements Criterion 50Hz 60Hz Voltage V 380 415V 10 460 480V 10 Phase 3 FLA A 23 MCA A 26 MOPD A 40 SCCR kA 12 Note This information can also be fo...

Page 21: ...otective gear and using properly insulated tools Before attempting to make any electrical connections or disconnections to the chiller Verify that the chiller s main circuit breaker disconnect handle...

Page 22: ...trical Enclosure Bottom View Inside Chiller QUARTER TURN LATCH E STOP BUTTON CONTROLLER ON OFF SWITCH CHILLER FAULT LIGHT RED QUARTER TURN LATCH SUPPLY MAINS CONDUIT CIRCUIT BREAKER DISCONNECT HANDLE...

Page 23: ...Installation Electrical Supply Mains 21 Figure 9 Electrical Panel Simplified CIRCUIT BREAKER DISCONNECT 3 PHASE POWER LABEL GROUNDING LUG Hypertherm Inc Part Number 810540...

Page 24: ...a cutting system 3 4 16 Male 37 Flare 8 JIC CAUTION It is highly recommended to use the hose kits supplied by the plasma cutting system manufacturer Exceeding recommended plumbing lengths can increase...

Page 25: ...and upper blocker panel as described in Section 6 4 2 2 Remove the fill port cap from the top of the tank 3 Fill the reservoir with the manufacturer s recommended fluid while monitoring the Tank Level...

Page 26: ...e information refer to Section 12 6 11 Installation Checklist Transport and Location of Chiller Unpack and check received chiller Sufficient clearance for intake and exhaust air has been maintained ar...

Page 27: ...to the main circuit breaker disconnect are not connected properly or if there is more than a 10 imbalance between phases the controller will display a Phase Monitor Alarm AL26 upon power up To correc...

Page 28: ...r 7 2 1 2 Leak Check Thoroughly check all the plumbing hoses and fittings between the chiller and plasma cutting system to ensure no leaks are present Remove the filter panel from the side of the chil...

Page 29: ...from the plasma cutting system While in Standby Mode the refrigeration system will not run but the chiller will start the pumps and heater as needed to keep the water warm NOTICE While waiting for th...

Page 30: ...oller indicates Unit Off turn the Main Disconnect Handle to the Off position WARNING Do not service unit until power is secure Follow standard Lockout Tag out procedures After completing service turn...

Page 31: ...tenance Service 8 1 Navigation To navigate through the controller s screens At the main menu level Use the and buttons to select the desired option Press the button when the desired option has been se...

Page 32: ...3 1 Auto Reset Alarms Auto Reset Alarms are alarms that automatically reset when the condition that is creating the alarm goes away 8 2 3 2 Manual Reset Alarms Manual Reset Alarms are alarms that req...

Page 33: ...as been in the UNIT OFF status for more than 10 min and now has entered STANDBY mode were it will run the tank maintenance heater to keep the coolant warm The chiller can be turned on by switching the...

Page 34: ...information UNIT OFF DUE TO FAULT The chiller has turned off due to one or more faults Refer to the alarm codes in section 9 1 Alarm List for more information SHUTDOWN IN PROGRESS A shutdown has been...

Page 35: ...ons Delta Temp Difference between Inlet and Outlet Temperature Cool Dem Percentage ratio of combined cold and Coolant heat loads to cooling capacity of compressor at current operating conditions Hotga...

Page 36: ...k Tank Level Measured coolant reservoir level Figure 18 Monitoring Filter Status In Press Inlet pressure to the Fluid filter on the facility fluid circuit Out Press Outlet pressure form the fluid filt...

Page 37: ...erature Measure temperature of air entering the condenser coil Specific Heat Specific heat Constant of the Process Fluid refer to set points for fluid type selection Modbus Master Status If the heater...

Page 38: ...urrent operating condition Off Not required On Required Able to on off in Number of seconds before the compressor is able to start or stop Run Time Total time in hours the compressor has been operatin...

Page 39: ...r On heating Off not heating Overload Status of pump overload Ok overload is functioning normally Fault overload has tripped Out Temp Process fluid supply temperature In Temp Process fluid return temp...

Page 40: ...Expansion Valve 1 Steps Opening in Steps of the expansion valve Open Opening in percentage of expansion valve to the full open position Figure 28 Devices Expansion Valve 2 Evap Press Pressure of refr...

Page 41: ...Controller Devices 39 Figure 29 Devices I O Module Status Status for the controller s I O module Address Modbus address of the I O module Hypertherm Inc Part Number 810540...

Page 42: ...measure to be displayed on the user interface Figure 31 Setpoints Plasma system Outlet Flow Fluid Heat Transfer Fluid type Concentration Percentage of Heat Transfer Fluid vs water Operating Frequency...

Page 43: ...nu under the Maintenance Service option Figure 34 Maintenance Service About Under the ABOUT option OS Version Current Operating system version of the controller Boot Version Current Boot version of th...

Page 44: ...Total operating time in hours of the compressor Fan Total operating time in hours of the Fan Note These timers are also available in the DEVICES menu refer to Figure 21 Figure 38 Maintenance Service...

Page 45: ...ved as File name To export the most recent alarm log 1 Press the button when in this screen 2 Under Memory Type press the or arrow to toggle the export location INTERNAL will export the log onto the c...

Page 46: ...tioner may be necessary for the main power supply AL 019 High Pressure Fault Auto reset The maximum pressure for the refrigeration circuit has been exceeded and the high pressure switch has tripped Ve...

Page 47: ...igerant charge may be low Contact DTS Service AL 028 Process Flow Fault User reset The process coolant flow rate is below the minimum threshold 0f 0 4GPM Verify that all valves in the process fluid ci...

Page 48: ...electrical connector on the flow meter to ensure it is fully tightened If the fault persists contact DTS Service AL 039 Tank Level Sensor Err Auto reset The level signal from the ultrasonic tank leve...

Page 49: ...7 Ambient Temp Very High Auto reset The ambient temperature has exceeded the chiller s approved environmental conditions defined in Table 4 Wait for the ambient temperature to decrease to within the a...

Page 50: ...the inline heater is located is still too hot Allow the pipe surface to cool before attempting to reset the switch 6 Reinstall the cap on the temperature limit switch 7 Reinstall the air intake filter...

Page 51: ...itial startup and then periodically If plumbing connections between the chiller and plasma system hose lengths fittings valve positions etc have remain unchanged it is expected that the supply pressur...

Page 52: ...eps 1 Shut the chiller down by turning the Local Off Remote Switch below the controller to the O position 2 Access the chiller s air intake filter side refer to section 6 4 Internal Access 3 Locate th...

Page 53: ...Filter Cartridge 51 Figure 41 Chiller Internal Components Air Filter Intake Side HIGH PRESSURE SWITCH Y STRAINER FLUID FILTER HEATER LIMIT SWITCH RECIRCULATION CIRCUIT FLOW METER DRAIN VALVE TANK HEA...

Page 54: ...aintenance Replacing the Particulate Filter Cartridge 52 Figure 42 Chiller Internal Components Panel Side RESERVOIR FILL CAP RESERVOIR PROCESS PUMP RECIRCULATION PUMP Hypertherm Inc Part Number 810540...

Page 55: ...Chiller Data Tag Replacing the Particulate Filter Cartridge 53 11 Chiller Data Tag Figure 43 Chiller Data Tag Hypertherm Inc Part Number 810540...

Page 56: ...00 a m to 5 p m EST Monday to Friday Website https www dimplexthermal com 12 1 Service Support Team serviceteam dimplexthermal com 800 968 5665 ext 709 269 349 6800 12 2 Parts Department partsdept dim...

Page 57: ...14 Added SI units to AL021 in Table 9 J Roby 11 3 2018 D Updated warranty period from 18 mo S Kadosh 12 14 2018 E Added DoC to Appendix E Changed Original Translation English to Original Instructions...

Page 58: ...Appendix A P I Diagrams Refrigeration Schematic 56 Appendix A P I Diagrams Refrigeration Schematic Hypertherm Inc Part Number 810540...

Page 59: ...Appendix A P I Diagrams Plumbing Schematic 57 Plumbing Schematic Hypertherm Inc Part Number 810540...

Page 60: ...Appendix B Electrical Schematics Power Page 58 Appendix B Electrical Schematics Power Page Hypertherm Inc Part Number 810540...

Page 61: ...Appendix B Electrical Schematics PLC 59 PLC Hypertherm Inc Part Number 810540...

Page 62: ...Appendix B Electrical Schematics I O Module 60 I O Module Hypertherm Inc Part Number 810540...

Page 63: ...Appendix B Electrical Schematics Logic 61 Logic Hypertherm Inc Part Number 810540...

Page 64: ...Appendix B Electrical Schematics Electrical Panel 62 Electrical Panel Hypertherm Inc Part Number 810540...

Page 65: ...04669 CUT DIN RAIL 5 LG 1 19 204671 CUT DIN RAIL 12 LG 1 20 204672 CUT DIN RAIL 16 LG 1 21 204674 CUT WIRE WAY 29 LG 1 22 204675 CUT WIRE WAY 12 LG 1 23 204676 CUT WIRE WAY 13 LG 1 24 204677 CUT WIRE...

Page 66: ...F C Keep Fan 100 For 2 Min PID Regulation for Motorized Hot Gas Deadband 0 1 056 F C Gain 10 0 Integral Time 45 s Derivative Time 6 s LOP Setpoint 55 0 3 79 PSI bar Prepos Time 20 S EEV Settings 1 3 S...

Page 67: ...essure Transducer 4mA 0 0 0 00 PSI bar 20mA 300 0 20 68 PSI bar Filter Inlet Pressure Transducer 4mA 0 0 0 00 PSI bar 20mA 100 0 6 89 PSI bar Filter Outlet Pressure Transducer 4mA 0 0 0 00 PSI bar 20m...

Page 68: ...t 240 16 54 PSI bar Inhibit Time 3 s Tank Level Warnings and Faults Warning On At 60 0 Off At 80 0 Faults On At 40 0 Off At 60 0 Low Refrigeration Pressure Fault On At 25 0 1 72 PSI bar Off At 50 0 3...

Page 69: ...Appendix C Default Controller Settings 67 I O Module Table 15 I O Module Default Settings Address 5 DIP Switch Settings Hypertherm Inc Part Number 810540...

Page 70: ...th Seller approval within said warranty period If the equipment is returned to Seller s factory the unit must be returned freight prepaid with prior approval from Seller with Buyer having obtained a r...

Page 71: ...extra charges incurred Warranty Parts All replacement parts under warranty must come from Dimplex Thermal Solutions When it is necessary for DTS to replace parts which are under warranty we will issu...

Page 72: ...Appendix E Declaration of Conformity 70 Appendix E Declaration of Conformity Hypertherm Inc Part Number 810540...

Page 73: ...Appendix E Declaration of Conformity 71 Hypertherm Inc Part Number 810540...

Page 74: ...Appendix E Declaration of Conformity 72 Hypertherm Inc Part Number 810540...

Page 75: ...Appendix E Declaration of Conformity 73 Hypertherm Inc Part Number 810540...

Page 76: ...ovide a reliable chiller service network across North America please register the chiller s site location with our inside service team The team will map your location and make efforts to provide a rel...

Page 77: ...l Support serviceteam dimplexthermal com Sales Department salesdept dimplexthermal com Assembled in USA ISO 9001 Certified 2625 Emerald Drive Kalamazoo Michigan 49001 800 968 5665 269 349 6800 dimplex...