含泵模块冷却器Folder 8_Rehsler_01-00 ab33006 Bedienungs- und Wartungsanleitung_EN-CN

1、Rehsler Kühlsysteme GmbHOperating and maintenance instructionsChiller with pump module含泵模块冷却器的操作与维护说明Edition 版次：2013Page: 20 of 20共20页，第20页Client 客户Reis GmbH & Co. KG MaschinenfabrikWalter-Reis-Str. 1D-63785 Obernburg徕斯机器人德国有限公司沃尔特徕斯大街1号奥伯恩堡，邮编D-63785Manufacturer 制造商Rehsler Kühlsysteme

2、 GmbH Bregenzer - Str. 13088131 Lindau/B林道/博登湖，邮编88131Customer order no. 客户订单号32 13 91 FAW II Chengdu 成都Rehsler job no. 工号33006Delivery date 交付日期Week 27/20132013年27周Commissioning 调试By Rehsler by arrangement or following completion of the installation be the customer, expected to be in October 2013调试

3、由Rehsler进行，布局或随后的安装由客户完成，预计时间为2013年10月。Overview of contents: 目录：A) Function 功能1.0Important information 重要信息Page 页码31.1Plant concept 装置理念Page 页码42.0Components 部件Page 页码5B) Switching on the plant 开启装置1Before commissioning 调试前Page 页码112Switching on the plant 开启装置Page 页码123Malfunctions 故障Page 页码14C) Mai

4、ntenance 维护C2)Maintenance schedule chiller维护计划 冷却器Page 页码16C3)Maintenance schedule - pump module维护计划 泵模块Page 页码17A)Function 功能1.0Important information 重要信息The cooling plant may be operated only by qualified, instructed technical personnel and only after having read this manual.冷却装置仅能由合格的且经过训练的技术人员进行

5、操作，并且操作前须阅读本手册。The hydraulic and electrical components may only be installed, connected or wired by persons who are qualified to do so.液压和电气部件仅能由有资格的人员进行安装、连接或布线。It is imperative to read the attached manufacturers documentation regarding this point!必须阅读有关这方面内容的随附制造商文件！Make sure that the operating wa

6、ter fulfils the conditions specified in the appendix (checking the water quality).确保操作用水满足附录规定的条件（检查水质）。Water that is too hard can very quickly lead to the deposition of limescale, resulting in damage to the plant and endangering the correct operation of the plant!水质过硬可非常快速地造成水垢沉积，从而会损坏装置，并危及装置的正常运行

7、！1.1Plant concept 装置理念The fundamental design of the cooling circuit corresponds to flow diagram no.33006.冷却回路的基本设计符合流程图33006。The design corresponds to a dual circuit pumping system with a buffer tank. The system pumps convey the cooled water from the buffer tank to the cooling points (cooling tunnel

8、s = conveyor).该设计对应一个双回路泵送系统以及一个缓冲罐。系统泵将缓冲罐中的冷水运到冷却点（冷却隧道 = 输送机）。The chiller pumps convey the heated plant return water from the buffer tank to the chiller.冷却器泵将缓冲罐中的加热装置回水运到冷却器中。The supply of recooled water takes place via a cooling and piping system provided by the customer.通过客户提供的冷却和泵送系统供应再冷却水。Co

9、oling water flow rate冷却水流量130.0m³/hCooling water inlet temperature冷却水入口温度35.0°CCooling water outlet temperature冷却水出口温度40.0°CCooling water pressure, min.最小冷却水压力2.0bar2.0Components 部件The essential components of this plant are as follows:本装置关键部件如下：2.1Chiller type Neptun NET 180 - R410a 冷

10、却器型号Neptun NET 180 - R410a- see chapter 6.01 见第6.01章2.2Pump module 泵模块 2.2.1 Buffer tank, 1500 litres 1500升缓冲罐2.2.2 Chiller pumps 冷却器泵2.2.3 System pumps 系统泵2.2.4 Electrical control cabinet 电气控制柜2.2.5 Pump controller 泵控制器2.2.6 Water level monitor 水位监测器 2.1Chiller type Neptun NET 080 - R410a 冷却器型号Nept

11、un NET 080 - R410aTECHNICAL DATA FOR CHILLER, WATER-COOLED水冷式冷却器技术数据*Attainable cooling power 可达到的冷却功率622.0KWMax. ambient temperature 最大环境温度45.0°CMin. ambient temperature 最小环境温度5.0°CCold water temperature 冷水温度12.0°CWarm water temperature 温水温度17.0°CWater flow rate 水流量103.0m³/

12、hEthylene glycol content 乙二醇含量0.0%Number of cooling circuits 冷却回路数量2-offNumber of compressors 压缩机数量6-offPower consumption of compressor(s)压缩机功耗40.0KWNumber of plate-heat-exchanger evaporators板式换热器蒸发器数量1-offMin. water flow rate 最小水流量29.0m³/hMax. water flow rate 最大水流量146.0m³/hVolume of plate

13、-heat-exchanger evaporator板式换热器蒸发器容量42.8litresNumber of plate-heat-exchanger condensers板式换热器冷凝器数量1-offMin. water flow rate最小水流量29.0m³/hMax. water flow rate最大水流量146.0m³/hVolume of plate-heat-exchanger condenser板式换热器冷凝器容积42.8litresCooling water flow rate (condenser)冷却水流量（冷凝器）130.0m³/hEt

14、hylene glycol content 乙二醇含量0.0%Cooling water inlet temperature 冷却水入口温度35.0°CCooling water outlet temperature 冷却水出口温度40.0°CCooling water pressure, min. 冷却水最小压力2.0barOutput control 输出控制0-16-33-50-66-83-100 % Voltage 电压400 V / 3-Ph / 50 HzControl voltage控制电压 230 V / 1-Ph / 50 Hz 240 V / 1-Ph

15、/ 50 HzPower consumption at operating point 操作点功耗140.0 KW Max. power consumption 最大功耗212.0 KW Current consumption 电流消耗348.0 A Start-up current 启动电流610.0 ADimensions 尺寸：Width 宽度800 mmDepth 深度3755 mm Height 高度1830 mmCold water connections flanges 冷水连接 法兰DN 80Cooling water connections flanges 冷却水连接 法兰D

16、N 80Tare weight approx. 自重 2125 kg Sound pressure level at a distance of 10 m 距离10m处的声压级62.9 db(A) Tolerance 公差+/- 2.0 db(A)*The sound pressure level was measured in the free field at a distance of 10 m to the compressor. The tolerance is +/- 2.0 dB(A)在自由声场距离压缩机10 m处测量声压级。公差为+/- 2.0 dB(A)。*2.2Pump m

17、odule 泵模块The pump module consists of the following components:泵模块包含以下部件：Pumps, fittings, measuring devices and sensors, water refill system and control cabinet. All listed components are fully piped and electrically wired泵、配件、测量仪器和传感器、补水系统和控制柜。所列部件均配有完整的管道和电线。2.2.1 Buffer tank 缓冲罐The buffer tank ser

18、ves as a temperature buffer, thus guaranteeing a high temperature constancy of the cooling plant and reducing the load changes of the chiller.缓冲罐作为一个温度缓冲器，保证冷却装置的温度保持高度稳定，并减少冷却器的负荷变化。The steel tank is galvanised and additionally plastic coated on the inside.The tank is equipped with suitable insulat

19、ion for the avoidance of condensed water.钢罐经过镀锌，内部涂有塑料涂层。缓冲罐配有适当的隔离层，防止冷凝水进入。2.2.2 Chiller pumps 冷却器泵The chiller pumps operate as single pumps and convey the heated circulation water from the tank to the chiller.冷却器泵作为一个单级泵，将缓冲罐中的加热循环水运到冷却器中。The pumps are protected against dry running by means of a

20、water level monitor.泵通过水位监测器防止空运行。Centrifugal pump NB 65 - 125/127离心泵NB 65 - 125/127Technical data 技术数据：*Manufacturer 制造商：Grundfos 格兰富Pump type 泵类型：NB65-125/127Flow rate 流量103.0 m³/hPumping pressure 泵送压力1.5 barMotor rating 电机功率7.5 KW Rated current consumption 额定电流消耗13 A Protection class 防护等级 IP

21、 55Voltage/current 电压/电流400 V / 3-Ph / 50 HzSuction nozzle 吸嘴DN 80 PN 16Pressure nozzle 压力喷嘴DN 65 PN 16*2.2.3 System pumps 系统泵Circulation pumps for consumers 用户循环泵The system pumps operate in parallel and convey the circulation water to the consumers.系统泵采用并行运行，并将循环水传输给用户。Centrifugal pump NB 50 - 125/

22、121离心泵NB 50 - 125/12150% parallel operation and 50% reserve50%并行操作，50%备用Technical data 技术数据：*Manufacturer 制造商：Grundfos格兰富Pump type 泵类型：NB 50-125/121Flow rate 流量69.0 m³/hPumping pressure 泵送压力1.4 barMotor rating 电机功率4.0 KW Rated current consumption 额定电流消耗7.3 A Protection class 防护等级IP 55Voltage/cu

23、rrent 电压/电流400 V / 3-Ph / 50 HzSuction nozzle 吸嘴DN 65 PN 16Pressure nozzle 压力喷嘴DN 50 PN 16*2.2.4 Electrical control cabinet 电气控制柜The corrosion-resistant control cabinet is manufactured and wired in accordance with applicable VDE directives. All components relevant for the regulation and control are

24、also connected to a separate terminal strip, allowing all operating conditions to be monitored by an external control room. The following plant components are integrated in the control cabinet:防腐蚀控制柜的制造和布线符合相应的VDE指令。所有与调控相关的部件还与单独的接线板相连，便于外部控制室监测到所有操作条件。控制柜中包含以下装置部件：- 1 Siemens S7 PLC- 1个西门子S7可编程控制器

25、- 2 pump motors 7.5 KW, 100% standby, cooling tower- 2个泵电机，7.5 KW，100%备用，冷却塔- 3 pump motors 4.0 KW, 50% standby plants- 3个泵电机，4.0 KW，50%备用装置- 4 pressure sensors IFM- 4个压力传感器IFM- 2 flow rate monitors- 2个流量监测器- 1 collective error indicator, operating indicator- 1个集合误差指示器，操作指示器All drives are completely

26、 wired with automatic circuit breakers, manual/automatic control switch, operating indicator lamps.所有驱动器与自动断路器、手动/自动控制开关、操作指示灯完成连线。2.2.5 Pump controller 泵控制器The pumps are controlled and monitored by a Siemens S7 PLC. The chiller is enabled for operation by the PLC.这些泵由西门子S7可编程控制器进行监控。通过PLC启动冷却器进行操作。

27、The PLC is installed in the control cabinet of the pump module.PLC安装在泵模块的控制柜中。- see chapter 5 见第5章2.2.6 Water level monitor (filling pressure monitor) 水位监测器（填充压力监测器）The filling pressure is monitored by a pressure sensor.填充压力由一个压力传感器进行监测。The pressure sensor is built into the supply pipe to the diaphr

28、agm expansion tank.压力传感器安装在的隔膜膨胀箱的供水管内部。- Volume of the diaphragm expansion tank is 80 litres- 隔膜膨胀箱的容积为80升。The diaphragm expansion tank serves to maintain the water pressure in the cooling system.隔膜膨胀箱用于保持冷却系统中的水压。Gas filling pressure 充气压力1.0 barPlant filling pressure, min. 装置最小填充压力1.2 bar Plant fi

29、nal pressure 装置最终压力3.5 bar Response pressure of safety valve 安全阀响应压力 4.0 barB)Switching on the plant 开启装置1.Before commissioning 调试前 1.1The stability of all components must be ensured.必须确保所有部件的稳定性。The chiller must be standing absolutely horizontal in order to ensure proper operation of the plant.冷却器必

30、须保持完全水平，以确保装置正确运行。1.2The piping system must be filled with water and bled.管道系统必须装满水The minimum filling pressure (1.2 bar) must be present.必须存在最小填充压力（1.2 bar）。1.3The shut-off devices must be open.必须打开切断装置。1.4The external electricity supply must be connected.必须连接外部供电装置。1.5The consumers must be connect

31、ed.必须与用户连接。2.Switching on the plant 开启装置2.1The plant (chiller and pump module) is switched on on the control cabinet (touch panel) of the pump module by appropriate operation of the devices located on the control panel.通过适当操作控制面板上的装置，在泵模块控制柜（触摸屏）上开启装置（冷却器和泵模块）。Switching on step-by-step guide 开启步骤指南1

32、.)Chiller 冷却器1.1)Main switch ON 打开总开关1.2)Switch on the chiller on the control display button 通过控制显示按钮开启冷却器-> chiller is running 冷却器运行As soon as the chiller is switched on, the indicators OFF operation and Flow error appear on the operating display. These indicators extinguish automatically when t

33、he cold water pumps start up.一旦开启冷却器，操作显示屏上出现断开操作和流量错误的指示。当冷水泵启动时，这些指示自动消失。2.)Pump module 泵模块2.1)Pump module 2) both main switches to On泵模块2)两个总开关同时开启2.2)Execute an emergency stop reset in order to enable the emergency stop device and the plant执行紧急停机重置，以便启用紧急停机设备和装置2.3)Set Controller switch to inter

34、nal/external将控制器开关设为“内/外”2.4)Set the switches of all pumps to Auto将所有泵开关设为自动Check the direction of rotation of each individual pump检查每个泵的旋转方向After enabling the cold water pumps the chiller is enabled在冷水泵启动之后启用冷却器Note - operating condition at water temperatures over 32°C注 运行时的水温高于32°C*At wa

35、ter temperatures higher than 32 °C in the water circuit the chiller switches to the Unloading mode水回路中的水温高于32 °C时，冷却器转换到放空模式(Operation of 2 of the 6 compressors).（6个压缩机，有2个运行）。The consumer pumps are switched off automatically.用户泵自动关闭。The pumps are enabled again when the temperature falls b

36、elow 32 °C.温度低于32 °C时，再次启动泵。Malfunctions 故障：.If a malfunction is indicated, read the error message from the display and follow the troubleshooting instructions in the operating manual.如果显示故障，则阅读显示屏上的错误信息，然后遵守操作手册中的故障检修说明。Chiller:proceed from page 7 in section 7.17. 冷却器：按照第7页第7.17节继续。Pump m

37、odule:proceed from page 5 in section report.泵模块：按照第5页的报告继续。3.Actions to be taken in case of malfunctions 故障时须采取的措施3.1The temperature in the plant water circuit rises for no apparent reason.装置水回路中的温度无故上升。Possible causes:There is too little cooling water.Check the operating point of the pumps. The coo

38、ling water temperature is too high.可能的原因：冷却水过少。检查泵的操作点。冷却水温度过高。C)Maintenance 维护1.General 概述An expert must always be consulted in the event of failure of any functional components inside the cooling plant that cannot be explained by contamination or inadequate lubrication.如果冷却装置中的功能部件出现故障，并且故障原因不是污染或

39、润滑不足，则必须咨询专家。A safety inspection of all functionally relevant parts of the plant must be carried out at regular intervals.必须定期对装置的所有功能零件进行安全检查。2.Chiller 冷却器Maintenance of the chiller must be carried out in accordance with the attached installation, operating and maintenance instructions.必须按照随附的安装、操作

40、和维护说明进行冷却器的维护。3.Buffer tank 缓冲罐The tank must be inspected for external damage at regular intervals. The insulation must be inspected for damage.必须定期检查缓冲罐是否存在外部损伤。必须检查隔离层是否损坏。4.Pumps 泵Maintenance must be carried out in accordance with the manufacturers maintenance instructions. (See attached document

41、ation)必须按照制造商的维护说明进行维护。（见随附文件）5.Filling level pressure sensors 填充液位压力传感器Maintenance must be carried out in accordance with the manufacturers specifications必须按照制造商的规范进行维护。6.Three-way motor-actuated valve 三通电机控制阀Maintenance of the motor-actuated valve must be carried out in accordance with the manufac

42、turers specifications必须按照制造商的规范维护电机控制阀。7.Control cabinet 控制柜All fuses must be checked annually according to VDE regulations.每年必须按照VDE规范检查所有熔断器。8.Diaphragm expansion tank, 80 litres 隔膜膨胀箱，80升The gas filling pressure of the expansion tank is to be checked and refilled if necessary.须检查膨胀箱的充气压力，并在必要时再次填

43、充。Gas filling pressure: 1.0 bar充气压力：Plant filling pressure, min.: 1.2 bar装置最小填充压力Operating pressure, max.: 2.5 bar最大操作压力：C2)Chiller maintenance schedule 冷却器维护计划Chiller maintenance schedule 冷却器维护计划Refer also to the operating and maintenance instructionschapter 6.01page 51另见操作和维护说明第6.01章第51页What has t

44、o be checked 检查项目Daily每日Weekly每周Monthly每月every sixmonths每半年Annually每年Remark 备注- Check whether there are any alarmMessages- 检查是否有任何报警信息x- Check whether the water outlet temperature corresponds to the setValue检查出水口温度是否符合设定值x- Check whether the water inlet temperature corresponds to themachine model检查入水口温度是否符合机器型号x- Check whether the water inlet temperature is lower than the val