S A CWFL-1000 Industrial Chiller User Manual

S A CWFL-1000 Industrial Chiller

TY-JS-220607-001 CWFL-1000/1500/2000/3000 Industrial Chiller

Product Information

The CWFL-1000/1500/2000/3000 Industrial Chiller is a piece of equipment that provides cooling to industrial processes. It is designed to be used within the specifications outlined in the user manual to avoid equipment damage, injury, fire, electric shock, and other major accidents. The equipment should not be used in an explosive environment or installed in dangerous places with flammable gas.

Usage Instructions

Before using the equipment, read the user manual carefully and keep it properly so that you can refer to it whenever you need information. The following usage instructions must be followed:

• Only professional technicians should carry out the operation of the equipment.
• Handling, installation of pipes, electrical, operation, maintenance, overhaul, and other operations must be carried out by personnel with professional knowledge.
• The equipment must not be used beyond the range of manual specifications.
• The equipment must be firmly fixed during transport and installation to avoid tipping or falling.
• The power cable terminal must be equipped with the electric leakage and overload protection device according to the rated current indicated on the equipment nameplate.
• Transportation with liquid is prohibited.
• The equipment must be operated in a suitable environment with proper ventilation to ensure that the air inlet and outlet are not blocked.
• Before commissioning, gently move the motor impeller if the equipment isn’t used for a long time.
• The equipment is forbidden to be trampled on. Clean the air filter regularly.
• Make sure that the water supply pipe of the equipment is not blocked.
• Check the water pipe and the water pump to confirm that there is a proper amount of water entering the water pump and exhaust it through the water pump exhaust valve.
• Confirm that the state of the equipment is normal and safe
  before use.

Failure to take safety measures will result in death or serious personal injury. Contact with live parts can cause serious personal injury or death. The human body or the heat-labile articles must
keep away from the high-temperature area to avoid personal injury or property loss. Do not put fingers or other things into the gap of the equipment. Refrigerant leakage can cause minor personal injury or property damage.

FOREWORD

Thanks for your purchase of our product. Please read this manual carefully before using and keep it properly so that you can refer to it whenever you need information.
This manual is not a quality guarantee. Our company reserves the right to the interpretation of the correction of misprint and improperly described information and product improvement. The revised content will be edited into the reprinted user manual without prior notice.

Notice
In order to ensure your personal safety and avoid property loss, you must pay attention to this manual, but not limited to the following warning notices. General electric knowledge and safety standards should also be followed.

DANGER
Failure to take safety measures will result in death or serious personal injury.

installation of pipes, electrical, operation, maintenance, overhaul and other operations must be carried out by personnel with professional knowledge.
|

It is forbidden to be used beyond the range of specification

| It is forbidden to use the equipment beyond the range of manual specifications in order to avoid equipment damage, injury, fire, electric shock and other major accidents.
| It is forbidden to be used in the explosive environment| It cannot be flammable gas.| installed| in| dangerous| places| with

| Electrical connection|

•  The power supply must conform to the standard indicated in the nameplate or the manual;
• Use the standard cable, and select the standard wire diameter;
• The grounding wire must be installed and the connection must be reliable; otherwise, it will cause an electric shock or fire.

| It is forbidden to operate the equipment without a cover| There are live parts inside the machine. It is forbidden to operate without a cover, as there is a risk of electric

shock.

| Water-proof| Do not allow the equipment to be drenched or immersed in water, otherwise there may be a risk of short circuit

and electric shock.

| Maintenance and repair| The operation must be carried out after 3 minutes of cutting off the power supply, because the high-voltage charging part in the equipment is not discharged within 3 minutes. Working in a live state or working immediately

after shutdown will cause the risk of electric shock.

| Danger High Voltage| Contact with live parts can cause serious personal injury or death.
|

Danger Hot Surface

| The human body or the heat-labile articles must keep away from this high temperature area. Otherwise, it will

cause personal injury or property loss.

DANGER
Failure to take safety measures will result in death or serious personal injury.

Transport and installation

| The equipment must be firmly fixed during transport and installation. Otherwise, there will be a danger of tipping or falling.
|

Electrical protection

| The power cable terminal must be equipped with the electric leakage and overload protection device according to the rated current indicated on the equipment nameplate.
|

Stop running in abnormal state

| When the equipment is abnormal, as long as the cause is not clear, it is forbidden to start. Otherwise, there is a danger of damage, electric shock, fire, and injury.
| Do not put fingers or other things into the gap

of the equipment

| There are rotating parts inside the device. Do not put fingers or other things into the gap of the equipment. Otherwise, it will cause personal injury.

|

Refrigerant leakage

|

• When the refrigerant leaks, please make sure that the ventilation is available. Otherwise, it may cause anesthesia and suffocation if a large amount of refrigerant fills the enclosed space;
• Avoid contacting with skin, or it will cause frostbite.

DANGER
Failure to take safety measures will result in minor personal injury or property damage.

• The equipment is not allowed to be transported with liquid to prevent internal pipeline leakage.

|

Transport

|

• The equipment should be fixed firmly before transportation to prevent the equipment from moving due to vibration and external forces. If there is excessive vibration and external force, the internal equipment may be damaged.
• Tilt angle should be ≤45°.Otherwise, the refrigeration system will fail.

|

Operating environment

|

•  It is forbidden to use in special environments such as high temperature, humidity, strong electromagnetic interference, etc.
• The equipment must be installed in a place where there is no direct sunlight and away from the fire sources.

|

Installation

|

•  The equipment must be installed on a horizontal surface. Otherwise, the refrigeration system will fail;
• It is forbidden to place objects within 1 meters around the air inlet and 1.5 meters around the air outlet. If the air inlet

| | and the air outlet are blocked, the cooling ability that the equipment should have cannot be realized.
---|---|---

|

Before commissioning

|

•  Make sure that the water supply pipe of equipment is not blocked;
• It is necessary to check the water pipe and the water pump to confirm that there is a proper amount of water entering the water pump and exhaust it through the water pump exhaust valve, otherwise it will cause damage to the water pump;
• Confirm that the state of the equipment is normal and safe, otherwise there may be injury and damage.

| Gently move the motor impeller if the equipment isn’t used

for a long time

|

For equipment that has not been used for a long time, it may be difficult to start the pump at the first start. Please gently move the motor impeller before the equipment is powered on.

Warning| The equipment is forbidden to be

trampled on

|

Please do not step on or sit on the equipment. Otherwise, it may cause injury accidents such as falling or overturning

|

Clean the air filter regularly

|

• Clean the air filter at least once a week. If it is blocked, the cooling ability will decrease and the power consumption will increase, and the alarm will not work properly.

|

Equipment surface cleaning

|

• Please use cleaning agents that are non-corrosive to metals and plastics;
• Please keep the cleaning agent properly after cleaning to prevent liquid leakage;
• The container for storing the cleaning agent must be sealed completely to avoid danger.

|

No air blowing at the water outlet

|

A temp sensor is installed inside the water inlet, and it is forbidden to blow air inside the device with an air gun.

****| Wear protective gloves

during maintenance, inspection and cleaning

|

• The sharp edges of the condenser fins may cut the skin;
• The temperature of the internal compressor and refrigerant piping is very high, and direct skin contact may cause burns.

| Anti-freezing|

• When the ambient temperature is lower than 0℃ and the machine is shut down for a long time, it is necessary to drain the liquid and blow the water away in the system with compressed air, otherwise there is a danger of freezing and cracking the components and pipelines.
• When room temperature is lower than 0 ℃ , it is recommended to use antifreeze with a concentration of not more than 30% containing ethylene glycol or propylene glycol.

Overview

This product is an industrial cooling device designed and manufactured for laser cutting, laser welding, laser marking, laser engraving and other equipment that uses laser processing. It can provide a temperature-stable cooling medium for the above application scenarios.

The chiller is composed of a compressor, a condenser, a throttling device (expansion valve or capillary), an evaporator, and a water pump. Its working principle is that the chiller’s refrigeration system cools the water, and the water pump delivers the low-temperature cooling water to the equipment that needs to be cooled. Then the cooling water will take away the heat, heat up and return to the chiller, and then be cooled again and transported back to the equipment. In the refrigeration system of a chiller, the refrigerant in the evaporator coil absorbs the heat of the return water and vaporizes into steam. The compressor continuously extracts the generated steam from the evaporator and compresses it. The compressed high-temperature, high-pressure steam is sent to the condenser and later will release heat (heat extracted by the fan) and condense into a high-pressure liquid. After being reduced by the throttling device, it enters the evaporator to be vaporized, absorbs the heat of the water, and the whole process circulates constantly. Users can set or observe the working status of the water temperature through the temperature controller.

Model Illustration

Note: This model description only contains the description of the company’s main product codes, not all of them are listed. Please confirm with our company before ordering the specific model, our company has the final interpretation right about it.

Product Outlines & Parts

Note: This model description only contains the description of the company’s main product codes, not all of them are listed. Please confirm with our company before ordering the specific model, our company has the final interpretation right about it.

 Installation

1. Open the package and check whether the machine is in good condition and whether the accessories are complete.
2. Please ensure that the working voltage of the chiller is stable and normal.
   Because the refrigeration compressor is sensitive to the power supply voltage, the normal working voltage of our company’s standard products is 210~240V (110V model is 100~120V). If wider operating voltage range is necessary, customization is available.

Equipment installation conditions and requirements

1. It must be installed on a horizontal surface and not tilted.

2. The air outlet of the chiller should be at least 1.5m away from the obstacle, and the air inlet must be at least 1m away from the obstacle (See below diagram).

3. Do not install in harsh environments such as corrosive, flammable gas, dust, oil mist, conductive dust, high temperature and humidity, strong magnetic field, direct sunlight, etc.

4. Operating Environment
   Ambient Temperature| Ambient Humidity| Altitude
   ---|---|---
   0~40℃| ≤90%RH| ≤3,000m

5. Medium Requirements
   Cooling medium allowed by the chiller includes purified water, distilled water, high-purity water and other softened water. It is forbidden to use oily liquids, liquids containing solid particles, corrosive liquids, etc. Clean the filter element and replace the cooling water regularly (about three months is recommended) to ensure the normal operation of the chiller.
   When the chiller is stored with water at room temperature lower than 2 ℃, it is necessary to add anti-freezer in the chiller water tank. It is recommended to use antifreeze with a concentration of not more than 30% containing ethylene glycol or propylene glycol. After the temperature warms up, change to purified water, distilled water or other suggested cooling media, let the chiller run for 30 minutes to remove the residual anti-freezer and drain it, and then refill with unused circulating water.
   

6. Determine the direction of the pipeline layout according to the water inlet and outlet of the chiller, and ensure that the waterway is clean and free of impurities, so as to prevent impurities from entering the waterway and causing blockage or pump failure.

7. Plug in the power cord and turn on the power switch(It is forbidden to start without water).

8. After turning on the power switch, the circulating pump of the chiller starts to work. When the new machine is turned on for the first time, there will be more air bubbles in the pipeline, which will cause the machine to alarm occasionally, and it will return to normal after a few minutes of operation.

9. After starting the machine for the first time, check if the water pipes leaks immediately.

10. After turning on the power, if the water temperature is lower than the set temperature, it is normal that the cooling fan and other devices of the machine do not work. The temperature controller will automatically control the working status of compressors, solenoid valves, cooling fans and other components according to the set parameters.

11. As it takes a longer time to start over the compressor and other components, according to different conditions, the time is range from seconds to minutes, so do not turn off the power and again on frequently.

Electrical connection

1. Please select the cable based on the max. rated current indicated on the label of the chiller.
2. Recommended reference standard for power cord diameter selection.

Note
This data is provided according to IEC 60204-1 standard and only for reference. Standard cables must be used in the power cord.

• The main circuit of the power supply must be equipped with appropriate electric leakage and overload protection devices, and the chiller must be well grounded.
•  Less than ±10% of power supply voltage fluctuation and less than ±1Hz of frequency fluctuation are allowed, and keep away from electromagnetic interference sources.

Fill Water & Exhaust Air

1. Fill Water
   After the new machine is turned on, the air in the water pipe is emptied, and the water level of the water tank will drop slightly. In order to keep the water level in the green area, you can add water again. Observe and write down the current water level. After the chiller has been running for a period of time, observe the water level gauge again. If the water level drops significantly, check again if there is leakage in the water pipes.

2. Exhaust Air
   After adding water for the first time or replacing water, exhaust the air in the water pump to start use, otherwise the equipment will be damaged. The exhaust method is as follows： Method 1: Under the state of shutting down, after adding water, remove the water outlet from the laser circuit (OUTLET L) and connect the water pipe, drain for 2 minutes, and then install it firmly.
   Method 2 : Open the water supply inlet, after starting the machine (water flows), repeatedly press and fold the water pipe several times to drain the air from the pipe.
   Method 3: Loosen the air exhaust plug of the water pump (do not unscrew), and air is discharged until water flows out, and then tighten the air exhaust plug (See below diagram, only the exhaust position of the horizontal pump is shown. According to customer requirements and specific models, the pump will be different, and the exhaust position will also be different. For the specific situation, see the external mark of the pump).
   

Test-run Check

1. Check whether the pipeline connection is correct, and there must be no bubbling or water leakage;
2. Check whether the inlet and outlet water ball valves are open and the drain valve is closed;
3. Check the liquid level of the water tank;
4.  Confirm that the electrical wiring of the equipment is connected correctly;
5. Confirm whether the equipment is grounded.

Operating States &Parameters Adjustment

1. Temperature control panel introduction
   

2. Working status indicator of the temperature controller
   Refrigeration indicator: during refrigeration, the indicator is on; In constant temperature status, the indicator is off; During delay, the indicator flashes.
   Refrigerant solenoid valve indicator: the indicator is on when connected and it’s off when disconnected
   Heating indicator of the low temperature circuit: the indicator is on when connected and it’s off when disconnected.
   Heating indicator of the high temperature circuit: the indicator is on when connected and it’s off when disconnected.

3. Rapid adjustment:
   Press “SET” button to set the temperature of the low temperature circuit. The low temperature window indicates F0 (F1 in intelligent control mode) and the high temperature window flashes with real-time value. Press or buttons to change the value and save. Press “SET” button again to set the temperature of the high temperature circuit. The low temperature window indicates F4 (F5 in intelligent control mode) and the high temperature window flashes with real- time value. Press buttons to change the value and save. Press or “RST” button to save the data and exit.

4. Press key once to enter status display menu and it indicates to which suggests temperature of room temperature probe.
   Press  key twice to indicate t2 which suggests flow rate of the low temperature circuit. ((L/min, resolution rate=0.1)
   Press key twice to indicate t3 which suggests flow rate of the high temperature circuit. ((L/min, resolution rate=0.1)
   Press key three times to return to normal operation.

5. In the first connection, press button to cancel delay time and connect the compressor.

6.  User data setting (F0~F16 available):
   The and  buttons are for changing and storing data. The and buttons are for changing items. Press and hold “ SET ” and buttons simultaneously for 6 seconds to enter data setting. The lower window indicates “PAS” while the upper window indicates “00”. Press or and buttons to change the password (08). Press “SET” button. If the password is incorrect, the lower window will indicate F0 and then data changing is available. If the password is incorrect, it will return to temperature display. If there is no button pressed in 20 seconds, the temperature controller will automatically exit from the data setting status. Press “RST” button to save the data and exit.

7. Restore factory setting
   Press and or hold and buttons for 3 seconds and it indicates “eE” and the supplier data and user data will restore to default value. Continue to press those buttons for another 3 seconds, it will return to temperature display.
   

8. Parameter setting table
   ** Data| Function| Range| Default value| Description| Remark
   ---|---|---|---|---|---
   F0| Setting temperature of low temperature circuit| -20~40. 0℃| 25.0℃| **

Setting menu of low temperature circuit

|
F1| Temperature difference coefficient| -15.0- 05.| -02.0|
F2| Refrigeration return difference| 0.1~3.0℃| 0.8℃|

F3

| ****

Control mode

| ****

00~01

| ****

00

| 01=intelligent control mode 00=constant temperature control mode
F4| Setting temperature of high temperature circuit| -20~40.0℃| 30.0℃| ****

Setting menu of high temperature circuit

|
F5| Temperature difference coefficient| -15.0~5.0| -0.20|
F6| Refrigeration return difference| 0.1~3.0℃| 0.8℃|

F7

| ****

Control mode

| ****

00~01

| ****

01

| 01=intelligent control mode 00=constant temperature control mode
F8| Ultrahigh water temperature alarm| 1.0~60.0℃| 10.0℃| ****

Shared by high & low temperature circuit

|
F9| Ultralow water temperature alarm| 1.0~20.0℃| 15.0℃|
F10| Ultrahigh room temperature alarm| 40.0~50.0℃| 45.0℃|

F11

| Highest water temperature under intelligent control mode| ****

F12~40.0℃

| ****

30.0℃

| ****

Intelligent    control    mode valid

F12

| Lowest water temperature under intelligent control mode| ****

1.0℃~F11

| ****

20.0℃

F13| Password| 00~99| 08| | 00=cancel            password function
F14| Water flow alarm of low temperature circuit| 0.0~20.0| 2.0L/min| |
F15| Water flow alarm of high temperature circuit| 0.0~20.0| 0.5L/min| |
F16| Communication address| 1~247| 1| |

Alarm & Output Terminal

In order to guarantee the equipment will not be affected while abnormal situation happens to the chillers, the chillers are designed with alarm protection function.

1. Alarm output terminals and wiring diagram.
2. Alarm causes and working status table.
   Display

Condition

| Alarm code| Buzzer| OUT H1 、 H2| OUT H1 、 H3
---|---|---|---|---
Circulating pump works properly| | | DISCONNECTION| BREAKOVER
Ultrahigh ambient temperature alarm| E1| Sounds| BREAKOVER| DISCONNECTION
Ultrahigh water temperature alarm of laser circuit| E2| Sounds| BREAKOVER| DISCONNECTION
Ultralow water temperature alarm of laser circuit| E3| Sounds| BREAKOVER| DISCONNECTION
Ultrahigh water temperature alarm of optics circuit| E4| Sounds| BREAKOVER| DISCONNECTION
Ultralow water temperature alarm of optics circuit| E5| Sounds| BREAKOVER| DISCONNECTION
Ambient temperature sensor failure| E6| Sounds| BREAKOVER| DISCONNECTION
Water temperature sensor failure of laser circuit| E7| Sounds| BREAKOVER| DISCONNECTION
Water temperature sensor failure of optics circuit| E8| Sounds| BREAKOVER| DISCONNECTION
Liquid level alarm| E9| Sounds| BREAKOVER| DISCONNECTION
External input alarm 2| E10| Sounds| BREAKOVER| DISCONNECTION
Flow alarm of laser circuit| E11| Sounds| BREAKOVER| DISCONNECTION
Flow alarm of optics circuit| E12| Sounds| BREAKOVER| DISCONNECTION
---|---|---|---|---
Chiller power failure| | | BREAKOVER| DISCONNECTION

Note : The alarm output port is connected with a set of normally open and normally closed contacts of the relay inside the machine. The working current should be smaller than 3A while
the working voltage should be smaller than 300V.

Maintenance

The equipment must be shut down for maintenance, and the power supply must be cut off. The operation can only be carried out after 3 minutes, otherwise there will be a risk of
electric shock. When the room temperature is lower than 2°C, the internal water must be drained when the machine is shut down for a long time.

Remove Dust Regularly
Regularly disassemble the filter gauze for cleaning and use a compressed air gun to blow away the dust on the condenser (about 1 week is suggested and the air filter must not be
missing for a long time).
Guarantee Water Quality
A certain amount of impurities will accumulate in the filter element over a period of time, which will cause a decrease in water flow, or even a secondary pollution. Therefore, it is necessary to clean or replace the filter element regularly.

Simple Troubleshooting

Machine turned on but unelectrified

|  Power cord is not plugged in place|  Check and ensure the power interface and the power plug is plugged in place and in good contact.

Fuse burnt-out

| Open the electric box cover, check the fuse and replace with a spare one if necessary. Check whether the power supply voltage is stable; Check and ensure the power interface and the power plug are in good contact.

Flow Alarm, Use a water pipe to directly connect to the water outlet and inlet but still without water flowing

|

Water level in the water tank is too low

|  Check the water level gauge display, add water until the level shows in the green area; And check whether water circulation pipe leaks.

Flow alarm occurs while chiller is connecting toother equipment, but there is water flowing and no alarm when a water pipe is directly connected to the chiller water outlet and inlet.

| Water circulation pipes are blocked or a pipe bending deformation.|

Check water circulation pipe

Ultrahigh water temperature alarm.| Blocked dust gauze, bad

thermolysis

| Disassemble and clean the dust gauze regularly
Poor ventilation for air

outlet and inlet

| To ensure a good ventilation bfor air outlet and inlet
Voltage is extremely low or

unstable

| To improve the power supply circuit or

use a voltage regulator

Improper parameter settings on thermostat| To reset controlling parameters or restore factory settings
Switch the power on and off frequently| To ensure there is sufficient time for refrigeration

(more than 5 minutes)

Excessive heat load

| Reduce the heat load or use other model with larger cooling capacity
Ultrahigh room temperature alarm.| The room temperature is too high for

the chiller

| To improve the ventilation to guarantee that the machine is running

below 40℃ room temperature.

Serious problem of condensate water| Water temperature is much lower than ambient

temperature, high humidity

| Increase water temperature or to preserve heat for pipeline
Water drains slowly from drain port during water

changing

| Water supply inlet is not open|

Open the water supply inlet

Startup flow alarm| Bubble in the water pipe| Exhaust the air

Attachment – Schematic CWFL-1000

CWFL-1500/2000

CWFL-3000

Documents / Resources

| S A CWFL-1000 Industrial Chiller [pdf] User Manual
CWFL-1000 Industrial Chiller, CWFL-1000, Industrial Chiller, Chiller
---|---
| S A CWFL-1000 Industrial Chiller [pdf] User Manual
CWFL-1000 Industrial Chiller, CWFL-1000, Industrial Chiller, Chiller

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