SMART
CHILLEX 42
WATER RECIRCULATING CHILLER
MODEL: Smart Chillex 42
Sr.No. : HX4222/04/0002
INSTRUCTION MANUAL
HEXON Instruments (P) LTD.,
EL-91, MIDC Electronics Zone
Mahape, Navi Mumbai.
Pin- 400 710.
Table of Contents
Introduction ..........................................................................................................................................3
1.
Chillex 42 FEATURES .................................................................................................................5
2.
SPECIFICATIONS .......................................................................................................................6
2.A
General:..................................................................................................................................6
2.B
System: ..................................................................................................................................6
2.C
Indicators: ..............................................................................................................................6
2.D
Electronics: ............................................................................................................................7
2.E
Other Features:.......................................................................................................................7
Environmental Requirements ...............................................................................................................8
2.F
Power .....................................................................................................................................8
2.G
Physical Installation ...............................................................................................................8
2.H
Unpacking Instructions ..........................................................................................................8
3.
Set-Up Instructions .......................................................................................................................9
4.
Operating Instructions .................................................................................................................10
5.
Maintenance Requirements .........................................................................................................10
6.
Operator Interface .......................................................................................................................11
6.A
HOME screen ......................................................................................................................11
6.B
Second screen ......................................................................................................................11
6.C
Alert screen ..........................................................................................................................11
6.D
Operators Buttons ................................................................................................................12
7.
To set The Required Temperature ..............................................................................................12
8.
Troubleshooting errors ................................................................................................................13
9.
8.A
Low flow alert......................................................................................................................13
8.B
Low water level alert ...........................................................................................................13
Ac wiring diagram ......................................................................................................................14
10.
DC wiring diagram……………………………………………………………………… …14
10.Piping schematics ........................................................................................................................155
2
Introduction
IR Tech is dealing with the full range of analytical instruments like XRD, XRF etc., for the
past 70+ years. An essential requirement of such instruments is a water re-circulating chiller,
which is usually imported. These imported chillers are expensive, attract high import duties
and demand costly and time-consuming service back-up. To overcome such bottlenecks, IR
Tech had come out with an indigenously designed water recirculating chiller- ‘Chillex’.
Now moving forward into a new era of technological advancement, IR Tech has come up with
a new manufacturing unit HEXON Instruments. Here at HEXON we manufacture smart
and advance chiller - ‘SMART Chillex’, replacing our previous IR Tech ‘Chillex’ model
with many improvements.
Our ‘SMART Chillex’ is custom made to suit the requirements of heat loads. Its performance
is at par with their imported counterparts, while being economical. It has a display screen for
the LIVE status of chiller, which is customizable. An inbuilt smart technology featuring
alerts and system-cutoff during low water flow or low water level. ‘SMART Chillex’ is
backed-up by efficient and timely maintenance service.
The purpose of this instruction manual is to provide the users with correct procedures of
installation and operation, which are explained in subsequent sections.
3
READ INSTRUCTIONS CAREFULLY BEFORE USE
4
1.
Chillex 42 FEATURES
o
Custom made to meet the specifications of XRD or Any other load of similar capacity.
o
Inbuilt smart technology system with automated safety features for low flow and low
water level.
o
Digital display for live working status of system and alerts.
o
Rugged Polypropylene water tank and Brass pipe fittings for long and corrosion-free life.
o
Compact brazed plate heat exchanger (PHE) as evaporator for higher cooling efficiency
& Air-cooled condenser with aluminum fins.
o
Specially designed hose adapters for easy serviceability with no leakage even at high
water pressure.
5
2.
2.A
SPECIFICATIONS
General:
Sr. No.
2.B
Parameters
Values
1
Heat dissipation capacity
4200 kcal/h (Max.)
2
Fluid medium
Distilled water
3
Water Flow Rate
4 – 7.5 l/min (adjustable)
4
Supply Water Pressure
3 to 5 kg/cm2
5
Supply Water Temperature
15 to 25 °C (adjustable)
System:
Sr. No
2.C
1
Compressor
CR22K6M (1.5TR), 1 Ph
2
Refrigerant
R22
3
Condenser
Forced Air cooled
4
Evaporator
Compact Plate type Heat Exchanger
5
Water Tank Capacity
45 L
6
Display
Nextion 5” HMI
7
Tank Material
Polypropylene
8
Water recirculation pump
Rotary vane pump (Brass)
9
Temperature Control
Digital Setting & Readout (± 1 °C)
10
Water Piping
Braided PVC pipe 9.5 mm ID
11
Pipe Connection
3/8" BSP
12
Water supply connections
SS/ Brass Construction
13
Water supply connections
230V / 1 PH / 50 Hz
14
Physical dimensions
835mm(L)× 1200 mm(H) ×630mm(B)
Indicators:
1.
Main power and Pump
: Glow type (RED)
2.
Chilling Unit
: Glow type (WHITE)
6
2.D
Electronics:
Sr. No.
2.E
Components
1
Microcontroller PCB
2
5” HMI display
3
Membrane keypad
4
Flow sensor
5
Pressure sensor
6
Water level sensor
Other Features:
o
Safety time-delay for compressor re-start 3 minutes (adjustable)
o
Water filter of 100 micron at suction line of the pump
o
Compact brazed plate heat exchanger for high cooling efficiency.
o
Powder coated MS body for corrosion free use.
o
Castor wheels for easy movement.
7
Environmental Requirements
2.F
Power
WARNING! The SMART Chillex 42 must be properly grounded.
The Chillex42 must be connected to power through a DOL starter of L&T ML-0 or
equivalent type, that is properly installed and grounded. Consult a qualified person for
these power connections & grounding.
The Chillex42 should be connected to a separate 230 Volt, 1Ph, 50 Hz circuit. It is advisable
that, no other devices should be connected to the same circuit.
2.G
Physical Installation
The Smart Chillex 42 should be placed on a firm, level, and vibration-free surface with a
minimum of 50 centimeters free space at the rear, sides and top. The system should be
located with adequate ventilation and as near as possible to the target. The piping to the
target should have heat resistant insulation.
2.H
Unpacking Instructions
Unpack carefully and verify that you have received the following.
One completely assembled unit of Chillex42 connected with 6 meters of power cord.
One key to open the front panel door.
Vinyl braided hose pipe of 10 mm size (Each 5 meters long)
Unpack Chillex42 carefully and with a screwdriver, open the top cover and unscrew the bolts
provided on the tank cover. Remove all the packing materials from the tank, while taking care
not to disturb any refrigeration piping and the PHE assembly. Check all the screw fittings for
any looseness during transportation, if found tighten them.
8
3.
Set-Up Instructions
1. Connect the Load & Chiller using flexible braided hose pipe and put heat insulating sleeves
on both lines. Connect one of the insulated hoses from the supply nozzle on the back plate
to the heat Load (Target) and the other one from load to the return nozzle. (Refer to the
piping schematic diagram on page).
2. Clean the tank thoroughly with city water and then rinse the tank with distilled water.
3. Fill the tank with clean distilled water. Please make sure that the water is clear & without
any suspended solids.
4. Connect the power cord to the wall outlet through a DOL starter of ML 0 or equivalent type.
5. Open the Supply & Return valves at side of the unit.
6. Power up the system from the DOL starter. The Red lamp on the front panel will glow.
This means that system receiving power and Pump started running.
7. Now water starts recirculation through the Target. The display will glow and indicate
parameters as shown in Page No. 10. If any error occurs, then go to troubleshooting Page
No 12. Check for any leakage. If found any, open, and re-tight them. After three minutes
the compressor starts working and the RED lamp on the front panel will glow. Let the
compressor work for approximately 10 minutes, or till it gets cut off at set value. Switch
the system to OFF position.
8. The set point of the temperature controller can be adjusted. Refer to Page No. 11
9. Switch OFF the system from DOL starter.
10. This completes the setup of Chillex42.
9
4.
Operating Instructions
1. Switch ON Smart Chillex42 through the DOL starter. Immediately the red lamp will glow
indicating pump has started, and the display will show the following parameters as shown in Page
No. 10
A. Flow rate
B. Pressure
C. Water level
D. Process temperature
2. The Chiller (compressor & condenser fan motor) will start 3 minutes after power ON. This will
be indicated by YELLOW lamp on front panel. This delay is given before every restart of the
chiller as a safety feature. The Chiller cut off occurs at the set value of the temperature controller
& it will restart again at 2 ºC above the set value OR after 3 minutes after the cut off, whichever
is later.
5. It is advised that, the X-Ray or Load should be put ON only after the first cut-off of chiller occurs
(refer Test Report for approximate time taken for first cut off).
5.
Maintenance Requirements
Clean the tank and inside mountings like temperature probe, inlet outlet hose.
Change the de-ionized distilled water once in three months.
Change the suction filter cartridge inside the tank once in six months or if it is found dirty,
to avoid starving of the re-circulating pump.
No other periodic maintenance is required.
10
6.
Operator Interface
6.A HOME screen
HOME screen or front page on the display consist of following parameters.
Flow rate in liter per minute
Water line pressure in kg/cm2
Tank water level in percentage
PROCESS : - Supplied water temperature
SET
6.B
: - Set value of require temperature
Second screen
Generally, the back page will display only for specific requirement which is discussed in Next
Page in the topic “To set The Required Temperature”.
6.C
Alert screen
Error screen will be pop up only when system has following errors.
1. Low flow
This alert will appear when there is low water flowing
through the system.
Troubleshooting for this is discussed in Page No. 12.
2.
Low water level
This alert will appear when there is low water
level in buffer tank.
Troubleshooting is discussed in Page No. 12
11
6.D
Operators Buttons
Press SET button to move to Second page where you can set temperature of
requirement.
Press RAISE button to increase the set temperature.
Press LOWER button to increase the set temperature.
Press ENTER button to verify the set temperature in display.
7.
To set The Required Temperature
From the HOME display:-
Step 1.
Press
the button. The display moves to
second screen. The following screen will appear.
Step 2.
Press
to raise the setpoint.
Press
to lower the setpoint.
Press
to confirm the value. After this only you will be able to see the final value
on the display on the screen.
Step 3.
Press
to send value to system. After this your setpoint will we modified one.
12
8.
Troubleshooting errors
8.A
Low flow alert
If this alert displayed on the screen, there will be following possibilities.
There can be a resistance in the in the system. System includes target and chiller itself.
A)
First check the piping connecting chiller and target. There may be a blockage to free flow.
B)
Check the chiller separately by connecting inlet directly to outlet. If this resolve the error,
then there is a restriction to flow in target. Contact instrument person to discuss the
problem.
C)
If chiller itself showing less flow eve after shorting, then there is high chance that water
filter cartridge in the tank is clogged. Change the filter immediately.
D)
If all the options above (A, B, C) don’t solve the problem then contact the service person
of chiller.
8.B
Low water level alert
This alert only showed when water level in tank below 40% of total capacity.
Refill the tank with distilled water up to required quantity.
Each time after taking actions against these errors, restart the system.
13
9.
Ac wiring diagram
10. DC wiring diagram
15
11. Piping schematics
16