NOVAtech
OPERATION
&
TROUBLESHOOTING MANUAL
Itech Cooling Systems
Hadimkoy Mah. Ataturk San. Sit. Niyaz Sok. No: 12 Hadimkoy / ISTANBUL/TURKEY
Tel: 0212 549 11 99 Fax : 0212 549 41 30 Web : www.ayteksogutma.com
e-mail : info@aytekchillers.com
NOVATECH 3-30 USER MANUEL
FORM NUMBER: 500_FRM.025
REV. NO:02 REV.DATE : 22.03.2018
CONTENS
1
1.1
1.2
1.3
- GENERAL FEATURES
- INTRODUCTION
- APPLICATION FIELD
- OPERATIONAL LİMİT
1.4 - TECHNICAL SPECIFICATIONS
1.5 2 2.1 2.2 2.3 2.4 3 3.1 3.2 3.3 4 4.1 4.2 4.3 4.4 4.5 4.6 4.7 4.8 4.9 4.10 4.11 4.12 4.13 5 5.1 5.2 5.3 6 6.1 6.2 6.3 7 8 8.1 8.2 -
SAFETY INFORMATIONS
INSTALLATION
MOVING THE UNIT
LOCATING YOUR UNIT
WATER CONNECTIONS
POWER SUPPLY CONNECTIONS
START-UP PROCEDURES
PRELIMINARY INSPECTION
WATER FILLING
STARTUP
GENERAL INFORMATION
COOLING EFFICIENCY
COMPRESSOR
CONDENSER
EVAPARATOR
TANK
POMP
FAN
LOW PRESSURE MANOMETER
HIGH PRESSURE MANOMETER
QUALITY OF THE CIRCULATING WATER
COOLING CIRCUITS
ANTIFRREEZE IN THE COOLING CIRCUIT
REFRIGERANT GAS
TROUBLESHOOTING
ALARM LİST
ALARM RESET
RETURN TO MAIN SCREEN
MAINTENANCE AND PERIODIC CHECKS
WEEKLY SERVICE
MONTHLY SERVICE
ANNUAL MAINTENANCE
WARRANTY
DIAGRAMS
HYDRAULIC CIRCUIT & REFRIGERANT CIRCUIT DIAGRAM
WIRING DIAGRAM
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NOVATECH 3-30 USER MANUEL
FORM NUMBER: 500_FRM.025
REV. NO:02 REV.DATE : 22.03.2018
1- GENERAL FEATURES
Your portable chilling system has been carefully assembled and engineered to give trouble free
service with a minimum of maintenance. The NTC series is produced in twenty five(25) different
models and capacities. Your unit is self-protecting by a series of safety controls integrated in the
control system. These have been timely set to obtain both adequate protection and optimum
efficiency from your unit.
1.1- INTRODUCTION
THIS HANDBOOK AIMS TO PROVIDE THE CUSTOMER WITH THE INSTRUCTIONS ON
COMMISSIONING-OPERATING- MAINTENANCE OF ITECH CHILLER DEVICES
1. Water temperature is controlled by adjusting the thermostat. Since this is sensing from the chiller vessel
inlets it could be set from the digital thermostad display. However, ON NO ACCOUNT must the leaving
water temperature be less than +50C. Unless a glycol solution is used and adjustments are made to the
controls by a qualified refrigeration serviceman.
2. Other than the thermostat, adjustment of controls and valves by unqualified personnel is done at a very
severe risk of permanent damage to the unit loss of efficiency.
3. NOVATECH models are self contained, industrial grade portable chiller that comes complete with pump
and tank. This full featured chiller is available from 2.000 to 541.000 kcal/h and is designed for indoor&
outdoor location. Each NOVATECH is fully wired, charged with 410A refrigerant, and factory tested under
load conditions to ensure easy installation and start-up.
1.2-APPLICATION FIELD
These units have been designed to provide cold water (or, for lower than +50C temperature, water and
antifreeze - see part 4.12) for use in industrial field applications.
WARNING : THE MANUFACTURER DECLINES ALL RESPONSIBILITY FOR DAMAGE OR INJURY
RESULTING FROM DIFFERENT PURPOSE
Water Outlet Temperature: min. -5 0C max +25 0C;
Ambient Temperature: min. +5 0C max +35 0C;
INFO : PLEASE REFER TO YOUR TECHNICAL SERVICE FOR DIFFERENT TEMPERATURE MENTIONED
ABOVE
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FORM NUMBER: 500_FRM.025
REV. NO:02 REV.DATE : 22.03.2018
1.3-Operational Limits
Evaporator
Minimum
Start-up Water Inlet Temperature
(°C)
7,5*
Water Outlet Temperature During Operation
(°C)
5**
Water Inlet - Outlet Temperature Difference
(K)
3
Condenser
Minimum
Full Load Air Inlet Temperature
(°C)***
-10
Partial Load Air Inlet Temperature
(°C)***
-10
Hydraulic Kit
Minimum
Pump-less Kit Air Temperature
(°C)
-20
Pump Kit Air Temperature
(°C)
-10
Pump Kit with Freeze Protected Air Temperature
(°C)
-20
(Table:1)
Maksimum
30
25
10
Maksimum
46
48
Maksimum
-
MAXIMUM TEMPERATURE VALUES MUST NOT BE EXCEEDED
*In the case that water inlet temperature is below 7.5°C, please contact ITECH.
**Solutions with antifreeze should be used in operations when water outlet temperature is below 5°C.
***In the case that air temperature is below -10°C, please contact ITECH.
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FORM NUMBER: 500_FRM.025
REV. NO:02 REV.DATE : 22.03.2018
1.4. TECHNICAL SPECIFICATIONS
COOLING
CAPACITY Kcal/h
FAN
AIR FLOW
m3/h
NTC 2
2000
1
40
480
x
600
x
890
NTC 3
3000
1
40
670
x
1010
x
1130
NTC 6
6000
1
40
670
x
1010
x
1130
NTC 10
10000
1
100
670
x
1010
x
1130
NTC 18
18000
1
100
670
x
1400
x
1300
NTC 25
25000
1
100
850
x
1400
x
1600
NTC 30
30000
1
220
850
x
1400
x
1600
NTC 40
40000
1
220
1050
x
2000
x
1950
NTC 50
50000
1
240
1050
x
2000
x
1950
NTC 61
61000
2
240
1050
x
2000
x
1950
NTC 80
80000
2
450
1375
x
2650
x
2000
NTC 104
104000
2
450
1375
x
2650
x
2000
NTC 123
123000
2
666
1375
x
2650
x
2000
NTC 140
140000
2
750
1500
x
2800
x
2450
NTC 160
160000
2
750
1500
x
2800
x
2450
NTC 175
175000
4
750
2350
x
3500
x
2450
NTC 210
210000
4
750
2350
x
3500
x
2450
NTC 244
244000
4
750
2350
x
3500
x
2450
NTC 280
280000
4
750
2350
x
3500
x
2450
NTC 315
315000
4
Opsiyonel
2350
x
3500
x
2450
NTC 352
352000
4
Opsiyonel
2350
x
5000
x
2450
NTC 386
386000
4
Opsiyonel
2350
x
5000
x
2450
NTC 421
421000
4
Opsiyonel
2350
x
5000
x
2450
NTC 481
481000
4
Opsiyonel
2350
x
6500
x
2450
NTC 541
541000
4
Opsiyonel
2350
x
6500
x
2450
MODEL
DIMENSIONS (W x L x H)
(Table:2)
(*) The manufacturer reserves the rights to modify any product specification without notice or obligation.
(1) Referred to ambient temperature 250C and water outlet temperature 150C
1.5. Safety informations
Before starting installation, we urge you to carefully read through and follow the instructions provided in the
manual and the labels on your unit.
The manufacturer declines all responsibility for damage or injury resulting from failure to respect the safety
indications.
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FORM NUMBER: 500_FRM.025
REV. NO:02 REV.DATE : 22.03.2018
1. The machine may only be used by trained personel who has been explicity assigned to use of it. While
mounting/demounting and servicing to the unit you should follow these instructions for safety
precaution.
2. Never block the fresh air inlets and warm air outlets.
3. Certainly the unit must not turn on while the upper and lower side panels are open. Otherwise there
could be serious injuries
4. Pressure in refrigerant circuit present in the unit can be hazardous when installing or servicing the
unit.(The unit comply with the EN60204-1 directives)
5. Before connecting the machine to the power outlet, ensure that the values stated on the identity
machine’s plate correspond to those of the power distribution system.
6. Safety grounding to the unit should be done according to EN60204-1 directive.
7. When the control panel is open you must not turn on the unit. Otherwise there could be serios
injuries.
8. ALWAYS use the individual protections while servicing the unit for operator safety recommended by
the Manufacturer: Protective overalls or apron, no slip waterproof shoes, rubber gloves, protective
eye-glasses and mask to protect the respiratory organs. To avoid accidents : before starting , remove
any jewelry, watches, ties or other accessories.
9. Not observing the rules reported on this manual, and every modification to the unit done without
explicit previous authorization, will cause the invalidity of the warranty.
10. The unit should be placed on a flat surface.While moving the unit on the sloping surface you must
use forklift or a crane.While moving the unit on the surface vibration could damage the copper gas
circuit.
2- INSTALLATION
2.1. Moving the unit
When the device is carried on the vehicle, put protective packaging between the device and vehicle's cabin
so that the electric panel and the body paint are not damaged.
If a forklift is to be used during shipment and installation of the device, a suitable forklift should be selected
according to the weight of the device. The forks of the forklift should be extended so as to protrude from the
other side of the device, the forks and the body should be checked so as not to damage anything, and the
device should be lifted in a balanced manner.
If a crane is to be used during the shipment and installation of the device, the device should be lifted by the
lugs at the top, in a balanced manner. It is useful to put soft material (EPS (Styrofoam), cardboard or cloth)
between the belt rope and device so that the paint of the device is not scratched. Crane ropes should be
adjusted not to give harm to control panel, electrical cables, fans and aluminum components.
If there is no lug, the device should be lifted by its four corners in a balanced manner.
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FORM NUMBER: 500_FRM.025
REV. NO:02 REV.DATE : 22.03.2018
THE CELL CONTAINING THE COMPRESSOR MUST NOT BE HANDLED UPSIDE-DOWN OR BY ITS SIDE,
OTHERWISE, THE COMPRESSOR GETS HARM.
CORRECT HANDLING METHODS
(Figure: 1)
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FORM NUMBER: 500_FRM.025
REV. NO:02 REV.DATE : 22.03.2018
2.2 Locating Your Unit
2.2.1. General precautions for installation location:
2.2.1.1. Select an installation location that meets the following requirements.
•
It is recommended that the unit be as close as possible to the process machinery.
•
Machine is suitable for outdoor installation.For indoor applications, hot air discharged by the fans
must be connected to an air duct which transfers the hot air to the open air. This is extremely critical
for high performance and to avoid high pressure breakdowns.
•
For outdoor installations fans and control panel should be protected with a cover roof located on
top of the fans minimum 2 meter distance between the fans and the roof cover. During winter,
antifreeze should be added to the water tank to avoid freezing.
•
Unit should be located in an easily accessible place for service, maintenance and cleaning of the
condensers.
•
Clearance for service is critical as the unit shall be placed away from obstructions for access to panels.
•
During operation, the air cooled unit must have adequate clearance around the condenser inlet for
fresh air movement and condenser outlet for hot air discharge. The distance between the roof and
fans must be 2 meters. The unit must be located 2000 mm away from the walls or any object
nearby.(see Figure: 3)
•
Proper air duct is required to avoid the absorption of the hot rejected air by the fan(s) which is critical
for the system performance.
•
As it is the case for all machines, air conditioning units cannot run completely silent. Their standard
noise levels for 1 meter are between 63 dBA and 76 dBA
•
They are the minimum distances to be left, and the device must n
•
ever be covered.
DISTANCE
(mm)
A
B
C
NTC 2-50
NTC 61-541
1000
3000
(max)
1000
2000
5000
(max)
2000
(Table:3)
(Figure:3 )
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FORM NUMBER: 500_FRM.025
REV. NO:02 REV.DATE : 22.03.2018
- The device is not allowed to be used in an explosive environment.
- The location of the unit should be selected such that the noise produced by the unit will not disturb anyone
according to the regulation.
- Consider the minimum and maximum water volumes and installation heights.
- In the case of a water leak, special care must be taken to ensure that the water does not cause any damage
to the installation site and surroundings.
2.2.1.2. Do not install the unit in the following locations:
- İn locations where sulfuric acids and other corrosive gases may exist in the atmosphere. Copper pipes and
brazed joints may corrode, causing the refrigerant to leak.
- İn locations where mist, spray or vapor of mineral oil may exist in the atmosphere. Plastic parts may break
and fall, or cause water leakage.
- The locations where there is an equipment that produces electromagnetic waves exists. Electromagnetic
waves may cause malfunctioning of the control system, which may prevent normal operation.
- The locations where thinner, gasoline and other volatile substances are processed and where flammable
gas leakage may occur, or where carbon dust and other incendiary substances exist in the atmosphere.
Leaked gas may accumulate around the unit and cause an explosion.
Choose a place protected from rain as much as possible.
-Make sure that the air inlet of the unit is not positioned towards the major wind directions. Wind blowing
from the front will disrupt the operation order of the unit. If necessary, use a shield to block the wind.
- Ensure that the water does not damage the area by adding a water drain to the sub-structure and prevent
water retention in the building.
- Ensure that the external unit is NOT EXPOSED TO direct sea winds. This aims to prevent corrosion caused
by high level of salt in the air that could shorten the unit's lifespan.
2.2.2. Air Duct
It is necessary to place an air duct on top of the fans to remove hot air discharge away from the unit to
prevent the unit from high pressure breakdowns, high electricity consumption and avoid loss of efficiency.
The height of the air duct is must be as indicated in TABLE 3.. The width and the length of the air duct should
be identical to the size of the unit. The diameter of the air duct must not be narrower than fan(s) diameter
dimensions at no section.For service convenience, it is recommended to install the air duct in a way that it
could be easily dismounted.
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FORM NUMBER: 500_FRM.025
REV. NO:02 REV.DATE : 22.03.2018
(Figure:4)
(Table:3)
DISTANCE
(mm)
A
B
C
NTC 2-50
NTC 61-541
1000
3000
(max)
1000
2000
5000
(max)
2000
The unit is not open to public use, install it in a safe area restricted from easy access.
This unit is suitable to be installed in commercial and light industrial locations.
2.2.3. Location in cold climates:
- To prevent exposure to wind and snow, place a deflector plate on the air side of the outdoor unit:
- Selecting an installation site in which snow will not affect the unit is very important in areas with very high
snowfall. If it is possible that snow falls from the side, make sure that the heat exchanger coil is not affected
by snow (if necessary, place a sidewall on the side) and that the air blown from the unit is not blocked.
- Install the unit high enough over the ground to prevent it from being covered by the snow (build a pedestal
if necessary).
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FORM NUMBER: 500_FRM.025
REV. NO:02 REV.DATE : 22.03.2018
2.3- Water connections
2.3.1.The connection of water pipes:
In units with manual water filling;
A plastic liquid level gauge has been installed on the tank to view water level.
All units are equipped with two chilled water connections.
a) Water to process
b) Water from process ( to water tank)
It is important that all external connections to be full size to minimize pressure losses.Water piping diameter
should be 1/2” larger than the pump outlet diameter. Plastic pipes avoid corrosion in the system and it is a
good isolation material. Therefore we strongly recommend plastic piping to be used for the water lines. If
metal pipes are used in the system, in order to avoid loss of cooling and drops of condensation, water pipes
shall be wrapped with thermal insulation material.
In case multiple machines will be fed from the main water lines, smaller diameter lines in between the main
water line and the machine(cooled water from the main line to the machine and return water from the
machine to the main warm water line) should be installed for each machine.For units between 30.000120.000 kcal/h range, in between line diameter size should be 3/4” where as for smaller size units ½”.
We recommend that a valve for each in between line shall be installed to adjust the proper water flow and
shut off the water to the machine in case there is need.
The water connections should be made by considering the water inlet and outlet according to the layout
scheme and in accordance with the related regulation. Problems may arise if dirt goes into the water circuit.
For this reason, always pay attention to the following points while connecting the water circuit:
-Use only clean pipes.
- Hold the end of the pipe down while removing the chips.
- Close the end of the pipe to prevent dust and dirt from getting into the pipe while installing the pipe through
the wall.
-Use a reliable external sealant to seal the connections. The seal must be able to resist against system
pressures and temperatures, and also it must be resistant to glycol used in the water.
-If metal pipes other than brass are used, isolate the two materials from each other to prevent galvanic
corrosion.
- Make sure that there is a proper drain for the pressure relief valve.
- Since brass is a soft material, use appropriate tools when making water circuit connections. Inappropriate
tools may cause damage to pipes.
- The unit should only be used in a closed-circuit water system. Application in an open water circuit may lead
to excessive corrosion in water pipes.
Do not use parts coated with Zn in the water circuit. Since copper pipes are used in the internal water circuits
in the unit, excessive corrosion may occur in these parts.
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FORM NUMBER: 500_FRM.025
REV. NO:02 REV.DATE : 22.03.2018
2.3.2. Isolation of water pipes
The complete water circuit including all pipes must be isolated to prevent condensation and decrease in
cooling/heating capacity during cooling operation, as well as to prevent freezing of external water pipes
during winter. Insulation materials must have a thickness of at least 13 mm at λ=0, 039 W/mK to prevent
freezing in external water pipes at -15°C of air temperature. If the temperature is over 30 °C and the relative
humidity is over RH 80%, then the insulation material must have a minimum thickness of 20 mm to prevent
condensation on the insulation.
2.3.3. Main installation diameters;
(Water Return )
Inch
(Water Outlet)
Inch
NTC 2
1
1
NTC 3
1
1
NTC 6
1
1
NTC 10
1
1
NTC 18
1
1
NTC 25
1
1
NTC 30
2
1
NTC 40
2
1
NTC 50
2
1
NTC 61
2
1
NTC 80
2
2
NTC 104
2
2
NTC 123
2
2
NTC 140
3
2½
NTC 160
3
2½
NTC 175
3
2½
NTC 210
3
2½
NTC 244
3
2½
NTC 280
3
2½
NTC 315
Opsionel
Opsionel
NTC 352
Opsionel
Opsionel
NTC 386
Opsionel
Opsionel
NTC 421
Opsionel
Opsionel
NTC 481
Opsionel
Opsionel
NTC 541
Opsionel
Opsionel
MODEL
(Table:4)
If more than one machine is to be installed, the diameter of the installation pipe for the machines must be
½" smaller than the diameter of the pipe in the main line. A ball valve must be placed in the main line for
water outlet and its return.
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FORM NUMBER: 500_FRM.025
REV. NO:02 REV.DATE : 22.03.2018
2.4- Power supply connections
MAKE SURE THAT THE POWER SUPPLY IN YOUR FACILITY HAS THE SAME FEATURES WITH THE
VALUES SPECIFIED ON YOUR DEVICE.
2.4.1. Electrical Installation Connection Preparation
➢ Check to ensure that power supply agrees with nameplate.
➢ Make sure the regularity of the voltage and current.
➢ It is not allowed to get current from device’s electric panel for other uses, and no internal modification
can be made in the panel.
➢ The following information is provided according to a distance of 20 meters between the main panel and
the device. Consult the technical service for information about cable diameters and fuse.
2.4.2 CABLE CONNECTION DIAMETER AND FUSE CAPACITY
MODEL
NTC 2
NTC 3
NTC 6
NTC 10
NTC 18
NTC 25
NTC 30
NTC 40
NTC 50
NTC 61
NTC 80
NTC 104
NTC 123
NTC 140
NTC 160
NTC 175
NTC 210
NTC 280
NTC 315
NTC 386
CABLE DIAMETER ( mm2)
3X2,5
3X2,5
5X2,5
5X2,5
5X4
5X4
5X6
5X10
5X10
4X16+10
4X16+10
3X25+6+10
3X35+10+16
3X50+10+16
3X50+10+16
3X70+10+25
3X95+16+35
3X95+25+35
3X95+25+50
3X95+70
FUSE CAPACITY (AMPER)
1x20
1X20
3X16
3X25
3X32
3X32
3X40
3X50
3X50
3X80
3X100
3X125
3X160
3X160
3X200
3X200
3X250
3X250
3X300
3X400
(Table:5)
➢ Electrical Panels are manufactured in accordance with TS 7936 EN 60335-2-40, TS EN 61000-6- 1/2/3/4
Standards and 2004/108/EC EMC Directive
IP44: PROTECTION FACTOR AGAINST THE CONDITIONS SUCH AS PRECIPITATION, SLEET AND DUST
DISPERSED BY WIND, AND ICING EFFECTS IN OUTDOOR USE.
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2.4.3. Electrical wiring installation
- All-pole main switches with a contact separation or another method of separation must be used in the
wiring installation, in accordance with the related regulation
- Use only copper cables.
- All wiring work on site must be conducted according to the electrical schematics supplied with the unit and
according to the instructions given below.
- Never clamp the wires in a bundle and make sure that they are not in contact with bare pipes and sharp
edges. Make sure no external tension is applied to the terminal connections.
- Power supply cables must be firmly fixed.
-Use a particular separated power circuit, never use a power supply that is shared with another equipment.
- If there is no N phase in the power supply or if it is faulty, the device will fail.
- Make sure you have a grounding connection. Do not ground the unit to an installation pipe, voltage pulse
attenuator, or telephone ground cable. Incorrect grounding may cause electric shock.
- Always install the necessary fuses or circuit breakers.
-Never remove thermistor, sensor etc. when connecting power cables to transmission cables.
(Compressor may be damaged if operated without thermistor, sensor, etc.)
3.START-UP PROCEDURES
3.1.Preliminary inspection
Check that:
- the main voltage and the power frequency correspond to the values stamped on the unit’s nameplate;
- the water pipes are rightly connected;
- the on-off valves of the pump’s suction line are opened.
- Fuses might be switched off during transportation, in such case, please open the electric control board and
move the switches to on position.
If your chiller is not run for a long time, the pump shaft may not rotate due to rust in the water pump,
tightening between gasket and shaft, or other reasons. In such cases, the device must be turned on
after ensuring the rotation of the pump to avoid any damage.
IF THE AMBIENT TEMPERATURE DECREASES UNDER 0 °C WHEN THE DEVICE IS OFF, REMOVE THE WATER
IN THE TUBES BY SWITCHING THE DISCHARGE VALVE UNDER THE TUBES TO PROTECT THE TUBES.
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3.2. Water filling
In EX versions filling up of water is performed automatically through the automatic filling valve or discharging
valve situated below the pressurised water tank and connected to the local water supply. Filling up the
system for the first time in the normal way may take even a few hours, but more rapid procedure would be
to connect to discharge valve.In this way, water is forced in, thus discharging the air by means of the water
pressure; when the filling finishes the automatic filling system may be actived and, the pump may be started
up.
In ST versions filling up water is performed manually through the filling pipe. Fill the tank with a hose until
the water level can be seen in the clear plastic fill tube.Keep topping up the tank until the water drops from
the overflow.As the water is circulated and fills the process equipment the water level will fall. Keep topping
up the tank until the water level is constant.
WARNING : IN CHILLERS WITH SHELL&TUBE EVAPORATORS, WATER PUMP SWITCH MUST BE
TURNED ON BEFORE STARTING COMPRESSOR.
WE SUGGEST YOU TO ADD SUFFICIENT QUANTITY OF MONOETHYLENE GLYCOLE TO PROCESS WATER
TO AVOID FREEZING WHEN THE REQUIRED WATER TEMPERATURE IS BELOW 70C AND OR WHEN THE
AMBIENT TEMPERATURE IS BELOW 50C.
(Figure:5)
(Figure:6)
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3.3. Startup
3.3.1. Starting
1. When the device is energized and the switch is set to "I" position, the temperature value will
appear on the screen.
2. Note the phase sequence, make sure that the phase protection relay provides output. After the
2 led lights (on and out) on the phase protection relay (KA1) are illuminated, the controller's
power will come on. If the phase protection relay (KA1) is out of LED lights and does not turn
on, the incoming electrical phases are reversed.
When you have connected the device to the mains, you should replace the two phase cables so
that the phase control relay (KA1) outputs.
Meanings of device lights
Voltage (s) within set limits
Temporary under voltage warning
Continuous under voltage warning
Temporary overvoltage warning
Continuous overvoltage warning
Both overvoltage and under voltage warning
İnsufficient supply warning
Phase sequence fault warning
light is on
light is off
Blinker
(Figure:7)
3. Switch on the control fuse and read that the voltage is on a normal value (380V, ± 5%) by a
measurement device. If the system has been standing for more than 24 hours, wait 12 hours in
this state.
4. To run the device, follow the steps below.
Press the [DOWN] key for about 3
seconds from the main display
<IMG INFO>
226,6
94,1
0
2
99,4
0
-1
The word OFF will appear on the
display.All other LEDs will be off
<IMG INFO>
226,65
97,55
0
2
10,6
-97,6
-1
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FORM NUMBER: 500_FRM.025
REV. NO:02 REV.DATE : 22.03.2018
5. After applying the above-mentioned procedure, the water pump of the device will operate and
it will supply water to the water line. When there is a water flow to the water line, the water
level in the device tank will get lower. Fill up the water tank by adding water.
THERMOSTATS ARE PROGRAMMED TO ALLOW THE DEVICE OPERATE AFTER 3 MINUTES AFTER
ELECTRIC CUT TO PROTECT THE MOTORS AND COMPRESSORS AGAINST INSTANT ELECTRIC CUTS.
3.3.2. Checking pump rotation
It is possible to verify the correct direction of
rotation of the pump impeller as indicated by the
arrow stamped on it, (figure 4) and, in case it is
incorrect, disconnect the power supply and invert
two of the phase wires for reverse the impeller
rotation.
Picture:1
3.3.3. Adjusting water outlet temperature
To Change the setpoint on your
machine, press the set key from the
main display
Pressing the set key once will open a
list of the various folders. Use the .UP.
and .DOWN. keys to scroll through the
menu and find the SP folder.
Press the set key to open the SP
folder. buttons to set the temperature to
the desired value
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FORM NUMBER: 500_FRM.025
REV. NO:02 REV.DATE : 22.03.2018
IF THE ABOVE INSTRUCTIONS ARE NOT FOLLOWED THE DEVICE WILL BE OUT OF WARRANTY.
THE TEMPERATURE INDICATED ON THE DISPLAY IS THE PROCESS FLUID
Please do not set the water temperature below +5 0C unless 25% mono etylen glycol mixture is added to the water
tank.
As the compressor start running, fans will automatically operate.Compressors will run until the desired water
temperature is obtained which can be seen from the digital thermostat display. Compressors and fans will
automatically shut off when the set temperature is achieved. In models with two compressors (twin independent
refrigeration circuits), compressors will start and stop seperately from each other according to the set temperature
values of each system. Fans will automatically stop only when both of the compressors shuts itself to off position.
The unit will start running automatically when the water temperature is 2 0C higher than the set value on the
thermostad display.
Please do not set the temperature value below +5°C before adding 20% mono-ethylene glycol (Antifreeze)
to the water tank. When the compressors start to operate, the fans are automatically switched on.
Compressors and fans stand by automatically when it is the desired temperature.
DISPLAYED WATER TEMPERATURE IS THE TEMPERATURE OF THE WATER TO BE PROCESSED.
.
3.3.4. How to turn off the unit
a) For the unit with micro processor control;
Press the [DOWN] key for about 3 seconds from the
main display
<IMG INFO>
226,6
94,1
0
2
99,4
0
-1
The word OFF will appear on the display. All other
LEDs will be off
<IMG INFO>
226,65
97,55
Turn off the power supply of the device by turning the main switch to position "0".
0
2
99,4
0
-1
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NOVATECH 3-30 USER MANUEL
FORM NUMBER: 500_FRM.025
REV. NO:02 REV.DATE : 22.03.2018
THE WARRANTY ON THE COMPRESSOR WILL BE INVALIDATED IF THESE INSTRUCTIONS ARE NOT FOLLOWED
FULLY.
IF THE ABOVE INSTRUCTIONS ARE NOT FOLLOWED THE DEVICE WILL BE OUT OF WARRANTY.
4. GENERAL INFORMATION
4.1- Cooling efficiency
Unit will work in high efficiency if :
✓ the water temperature is as high as possible, utensil machinery requirements permitting;
✓ an adequate water flow rate is provided (adequately sized piping);
✓ the unit fed with cool air
4.2-
Compressor
The compressor draws in the superheated refrigerant vapor and compresses it to a pressure and temperature
high enough that it can reject heat to another fluid. This hot, high-pressure refrigerant vapor then travels to
the condenser.
(Figure:8)
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4.3-
FORM NUMBER: 500_FRM.025
REV. NO:02 REV.DATE : 22.03.2018
Condenser
Within the condenser, heat is transferred from the hot refrigerant vapor to relatively cool
ambient air or cooling water. This reduction in the heat content of the refrigerant vapor causes
it to desuperheat, condense into liquid, and further subcool before leaving the condenser for
the expansion device.
Micro Chanel
Auminum
(Figure:9)
4.4-
Evaporator
The evaporator is a heat exchanger that transfers heat from air, water, or some other fluid to the cool liquid
refrigerant.
(Figure:10)
4.5-Tank
It is the part that works together with the evaporator to facilitate the circulation of the water
NTC 2
25
NTC 3-10 NTC 18
70
120
NTC 25
130
TANK CAPACITIES (LT)
NTC 30-NTC 50 NTC 61-NTC 160 NTC 175-280
200
350
600
NTC 315-NTC 541
Opsiyonel
(Table:6)
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4.6-
FORM NUMBER: 500_FRM.025
REV. NO:02 REV.DATE : 22.03.2018
Pump
The pump is used to bring the water from the tank to the evaporator, to be cooled in the chiller group. The
power of the pump, which circulates the cooling water through the copper pipes that provide heat transfer
in the evaporator and provides pressure to the water, must be selected compliant with the evaporator size,
thus according to the system's need for cold water.
(Figure:11)
4.7-
Fan
➢ They are aerodynamically structured
(rotor-motor type) direct-coupled
silent and high-efficiency fans that
work
safely
under
outdoor
conditions.
➢ The number of fans required to
operate can be set automatically by
means of the pressurestat control.
Do not check manually when the fan is running, do not check the rotor control, the direction of rotation
without being sure that it is completely stopped.
4.8-
Low-pressure manometer
The low-pressure manometer can be used to measure gas suction pressure at the device during the
operation.
4.9-
High-pressure manometer
The high-pressure manometer can be used to measure the compressor gas outlet line pressure.
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4.10-
FORM NUMBER: 500_FRM.025
REV. NO:02 REV.DATE : 22.03.2018
Quality of the circulating water
To maintain the quality of the circulating water, it is required to follow the values indicated in the table.
(Table:7)
4.11-
Cooling Circuits:
There are two separate cooling circuits on the devices with the capacity of 40,000 kcal/h and higher. The
electronic control panel turns on or off the two compressors automatically according to the needs of the
system. When one of the separate cooling circuits is out of order, the other will continue to operate until the
faulty one is serviced.
4.12-
Antifreeze in the cooling circuit
If the water temperature needs to be kept below +5 0C or if the ambient temperature may fall below 0 0C, it
will be necessary to add a certain quantity of antifreeze fluid in the form of pure monoethylene glycol.
The recommended ratios of the mixture are as follows:
%10 for water temperatures down to +3 0C
%15 for water temperatures down to 0 0C
%20 for water temperatures down to -3 0C
%25 for water temperatures down to -6 0C
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FORM NUMBER: 500_FRM.025
REV. NO:02 REV.DATE : 22.03.2018
GLYCOL MAY CAUSE CORROSION IN LONG-TERM USE, SO THAT ANTIFREEZE MIXTURE MUST BE REPLACED
EVERY YEAR.
POSSIBLE CAUSES OF MALFUNCTIONING
4.13. Refrigerant gas
The gases to be used in the device must comply with the standard and local regulations of the country where
the device is used.
407C : 407C is a mixture of three hydrochlorofluorocarbon and environmental friendly not depleting ozone
layer.The compent of 407C gas is % 23 R 32 + % 25 R125 + % 52 R134a. If any gas leakage is occured determing
the amount of gas is impossible.That’s why the gas must be depleted and charge it again.Performance
characteristic is similiar to R-22 gas.
R410A soğutucu kolaylıkla suyu emer, membran veya yağı okside eder. Basıncı R22’den yaklaşık 1,6 kez daha
yüksektir.
R410A: R410A refrigerant easily absorbs water, oxidizing membrane or oil. Its pressure is approximately 1. 6
times higher than R22.
134A: It is an HFC refrigerant that does not cause ozone depletion. It can be used as a pure refrigerant in
some of the conventional R-12 applications or as a component in refrigerant mixtures expected to replace R502 and R-22.
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FORM NUMBER: 500_FRM.025
REV. NO:02 REV.DATE : 22.03.2018
5. TROUBLESHOOTING
5.1-Alarm List
The alarm codes show up on the processor's digital display.
TROUBLE
ER00
(Phase Control Malfunction)
ER 01
ER 02
(High pressure alarm)
ER05 ER06
(-Low-Pressure Alarm)
ER10
ER11
(Thermal Failure)
CAUSE
- There is a problem with the
power supply voltage of the
device.
SOLUTION
- Check the energy connection
of the device.
- Clean dirty condener.(see
part 6)
- Feed the unit with fresh air.
- Check fans.
- Place a proper air duct to
discharge the hot air from the
unit.
- Turn off the appliance and call
your technical service.
-Compressor suction pressure is - Check the appliance’s water
low.
level in the water tank. Make
- Not enough water circulation sure that the filters are clean and
from chiller device.
valves are on in your water
supply.
- Dirty condenser.
- The ambient temperature is
higher than the working limit.
- Fan failure.
- Working without air duct or
wrongly designed.
The current drawn by the
compressor is actually more than
the current required to be
drawn.
- Check that the device is
supplied with 3 phase electric in
balance. Check that the power
supplied to the device is 400
V/50 Hz (+ - 10%) by measuring.
- Make sure that the fan's
electrical connection terminals
and contactor connection screws
are not loosened. Tighten the
loose screws. If there is damage
in the contactor feet, replace
with a new one. Check that all 3
phases pass through the
contactor.
- Measure the current drawn by
the pump with an ammeter.
Check the fan thermal setting. If
it is low, adjust it to the
appropriate amp setting.
- Clean dirty condener.(see part
6)
- After performing the above-mentioned procedure, reset the fault by applying the fault
(Picture: 2 or Picture: 3)
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NOVATECH 3-30 USER MANUEL
ER 15
ER 16
( Oil Pressure Alarm )
ER 20
Water flow alarm
EX versions only
ER 21
(Pump Thermal Alarm)
ER 30
(Antifreeze alarm)
EX versions only
ER35
(High temperature alarm)
Er40
Er41
Er42
(Fan thermal alarm)
FORM NUMBER: 500_FRM.025
REV. NO:02 REV.DATE : 22.03.2018
- The compressor is not
lubricating, oil level is too low or
oil is too hot.
- There is no water circulation in
-The state where the oil level in the system. Check the water
the compressor is less than circulation.
required.
- The sump heater is out of
order.
- Reset it by following the
instructions in Figure 8.
- Water flow rate is too low
- There are large quantities of
air trapped inside the circuit.
- Current absorption of pump or
compressor is higher than it has
to be.
- Insufficient water flow through
the evaporator.
- The desired water
temperature is set lower than
the working temperature
without antifreeze.
- High water temperature
- Check if the water pump is
working properly.
- Check if there is enough water
in the circuit.
- Otherwise turn off your unit
and restart it.
- Please turn off your unit and
call your refrigerant serviceman.
Check the water level.If needed
add
some
water.
- Set the desired water
temperature higher or add
sufficient antifreeze to cooling
water
- Replace the water in the tank
with fresh water
- Check that the device is
supplied with 3 phase electric in
balance. Check that the power
supplied to the device is 400
V/50 Hz (+ - 10%) by measuring.
- Check the fan motor tightening.
- Loose screws tighten. If there is
damage in the contactor feet,
The current drawn by the fan is replace with new. Check that all
actually more than the current 3 phases pass through the
required to be drawn.
contactor.
- With ammeter you can
measure the current drawn by
the pump
. Check the fan thermal setting.
If it is low, set it to the
appropriate amp setting.
- Check the fan motor tightening.
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NOVATECH 3-30 USER MANUEL
ER45
ER46
( Time lost alarm )
Er60
Er61
Er62
Er63
(Thermostat sensor alarm)
ER90
(Alarm Memory Full)
FORM NUMBER: 500_FRM.025
REV. NO:02 REV.DATE : 22.03.2018
- Reseting time memory by - Set timer on microprocessor
unexpectedly
again .
- Thermostat sensor failure
- Please turn off your unit and
call your refrigerant serviceman.
Your device will continue to
function normally. Perform the
The alarm memory of the following steps to clear the
microprocessor is full.
message code on the screen and
alarm
memory
of
the
microprocessor.
(Table:8)
YOUR COMPRESSORS MAY GET DAMAGED WHEN YOU ALWAYS RESET PRESSURE AUTOMAT WITHOUT
RECOVERING THE FAILURE THAT CAUSES HIGH-PRESSURE ALARM.
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NOVATECH 3-30 USER MANUEL
5.25.2.1
FORM NUMBER: 500_FRM.025
REV. NO:02 REV.DATE : 22.03.2018
Alarm Reset
To alarm reset and restart the unit,
Follow the steps described below in order(chapter:5.1). After fixing the causes of the high-pressure
failure(ER01) / low-pressure failure(ER05);
5.2.1.1.a. Manual reset type: Press the reset button on the pressure swich. (Picture 2a/2b)
5.2.1.1.b. Automatic reset type: There is an automatic reset. (Picture 2c).
5.2.1.2. After fixing the causes of overload failure, press the reset button on the thermal protection
relay. (Picture 3)
Picture 2(a)
Picture 2(c )
5.2.2. Then apply general alarm reset, by pressing keys
Picture 2(b)
Picture 3
at the same time.
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FORM NUMBER: 500_FRM.025
REV. NO:02 REV.DATE : 22.03.2018
5.3. DELETING ER90 ERROR MESSAGE (Alarm Memory Full)
Reset alarm log (folder EUr)
Press [esc + set] keys together at the
main screen. 'Par' will appear on the
screen. Press the Up/Down arrow
keys until you see 'FnC' and press
"set" key. 'dEF' will appear on the
screen. Press Up/Down arrow keys to
find 'EUr' file.
Press "set" button for 3
seconds [set]
"YES" will appear on the screen
to notice that the alarm record
is deleted.
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FORM NUMBER: 500_FRM.025
REV. NO:02 REV.DATE : 22.03.2018
5.4 Setting the clock (CL)
Microprocessor control has a clock (RTC) to run the alarm log and time bands, just like a programmable
chronothermostat. Instructions are provided below on how to set the time: the same procedure applies to change
the date and year.
To change the clock on your machine, press the set
key from the main display
Pressing the set key once will open a list of the
various folders.
Use the “UP” and “DOWN” keys to find the CL
folder.
Press the set key to open the CL menu.
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NOVATECH 3-30 USER MANUEL
FORM NUMBER: 500_FRM.025
REV. NO:02 REV.DATE : 22.03.2018
6.MAINTENANCE AND PERIODIC CHECKS
BEFORE EVERY OPERATION OF SERVICING ON THE UNIT, BE SURE THAT THE POWER SUPPLY IS
DISCONNECTED.COPPER TUBES CAN BE AT HIGH TEMPERATURE LEVEL.BE VERY CAREFUL WHEN
OPERATING IN ITS SURROUNDINGS.
THE SURFACES OF THE EXCHANGER COILS COULD BE VERY SHARP AND FRAGILE: BE VERY
CAREFUL WHEN OPERATING IN ITS SURROUNDINGS.BE ALSO CAREFUL FOR NOT DAMAGING IT.
ALL THIS OPERATION DESCRIBED IN THIS CHAPTER MUST BE DONE BY TRAINED PEOPLE ONLY:
WRONG EXERCISES OR SETTING VALUES OF CONTROL AND SAFETY DEVICES COULD CAUSE
SERIOUS DAMAGE TO THE UNIT AND INJURIES TO THE PEOPLE.AFTER SERVICING OPERATION
CLOSE THE UNIT WITH COVER PANELS, FIXING THEM WITH THE SCREW DRIVER LOCKS.
6.1. Weekly service
1. Checking for internal water leakages or condensation.
2. Check how dirty the condenser is
3. Check there’s no oil leakage in the gas circuit
4. Check the water level in the tank.Add water if there is a loss.
6.2. Montly service
Air dust particles cover the condenser within a time interval and blocks the air movement through the fan.
This will lead an increase of gas pressure in your system and will cause the compressor shut off automatically
against any damage that may occur due to high pressure.In such case, please check and clean condenser.
This should be done periodically as required depending on plant air conditions. Condenser inlet can be
cleaned by spraying air with an air compressor in between the aluminum fins.(figure 3)When you finished
cleaning the condenser you should remove dust with a vacuum cleaner.(figure 4)
Picture: 4
Picture: 5
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FORM NUMBER: 500_FRM.025
REV. NO:02 REV.DATE : 22.03.2018
WARNING: TAKE EXTRA PRECAUTION NOT TO DAMAGE THE COPPER PIPES DURING CLEANING
PROCESS.
6.3. ANNUAL MAINTENANCE
a. Carry out daily, weekly, and monthly maintenance as described.
b. Chassis and installation are cleaned if there is corrosion. If necessary, the paint is renewed.
c. The condenser fan blades are cleaned.
d. Contactor, thermal, fuse, connector etc. are checked, replaced with new if necessary.
e. Any filter etc. needs to be changed at freon circuit is replaced.
f. The protective equipment in the cooling system is checked if they are operational by controlling their
settings.
7.WARRANTY
7.1. General Alerts
NOVATECH chillers are warranted to the original purchaser for one full year from the date of invoice against
defects in material and workmanship.
This warranty does not apply to; improperly installed, handled, abused, failure to follow NOVATECH’s
operation and maintenance instructions, damaged in transport, nor to any unit which has been repaired or
altered by unauthorized agencies.
In case the repair of the heavy parts is not possible on site during the warranty period, the vertical, horizontal
handling, and portage works (crane, truck, weight etc.) related to bringing and delivering it to the ITECH
Factory is the User’s liability.
Materials that are periodically changed during the warranty period must be originally procured from ITECH.
Parts that need to be replaced periodically are not covered by the warranty, such as belts, filters, dryer
cartridges.
Warranty application does not grant any right to the customer to claim against ITECH COOLING SYSTEMS
Services. The Customer cannot claim compensation.
7.2. THE CONSIDERATIONS OF THE CUSTOMER REGARDING WARRANTY
ITECH Service personnel or the services authorized by ITECH will treat the devices covered by the
warranty. Damage caused by installation mistakes or by unauthorized persons is not covered by the
warranty.
The following are not covered by warranty either:
•
•
•
•
•
•
Damage caused by shipping and misplacement.
Damage caused by running the device out of operational conditions.
Defects arising from the use of spare parts and oil which are not acceptable.
Motor damage due to the selection of incorrect thermal, fuse, contactor for motors.
Damages that may be caused by the corrosive and acidic effect of the environment in which the
device is expected to operate (the fan shaft and rotors, and battery surfaces become unusable due
to rusting or corrosion)
Damages caused by external materials forgotten in the device or fan motor,
31
NOVATECH 3-30 USER MANUEL
•
•
•
•
•
•
•
•
•
•
FORM NUMBER: 500_FRM.025
REV. NO:02 REV.DATE : 22.03.2018
Complaints such as problems caused by lack of flexible material in duct connections, lack of acoustical
isolation materials in discharge channels, noise and flow inefficiency caused by incorrect calculation
of non-device pressure losses,
Flow problems due to improper channel design or incorrectly set parameters (flow, pressure) and
compressor failures due to these problems,
Maladjustment of the manual or automatic control settings of the exhaust and fresh air damper,
Damages that may occur during the process of handling,
The damage at elements that are before and after the heater due to high temperature, especially
when there is no thermostat control in devices with steam and electric heater.
Freezing of the battery when there is water in the battery at temperatures below 0 °C and the
antifreeze is not added,
Battery damages and knocking in steam batteries due to the selection of incorrect condenser or
unsuitable condense line.
Damages due to application of high pressure on the battery, higher than operating pressure
The determination of the technical methods to be applied to recover the failure and the
determination of the parts to be replaced is the responsibility of our Company. The failure can be
repaired at the place of the product or at an authorized workshop. Our client must approve it.
It is imperative that this document is submitted upon the request of the services. Otherwise, the
device becomes out of warranty.
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FORM NUMBER: 500_FRM.025
REV. NO:02 REV.DATE : 22.03.2018
PERIODICAL SERVICE CHART
ACTIONS
DAILY
Visual gas leakage and lubrication control
Check the oil levels
Water leakage control in water installation
Control of contamination in the filters at the water installation
Condenser contamination control
Gas pressure value control of the cooling device
Refrigerant leakage control
Check for refrigerant leaks
Gas piping connection fittings control
The electrical panel cable connection screws and sockets’ tightening
Check
controlthe voltage and current of the electric motors by measuring.
Contamination of system water and antifreeze value control
Tightening all electrical connection sockets and lugs
Compressor oil change and sump filter cleaning
Adjustment thermostat and safety control
Control of fan bearing and motor bearing
Control of drain tray and siphons
Electric voltage, contactor, auxiliary relay control
Compressor oil change and sump filter cleaning
Dryer change
Compressor valve plate replacement complete overhaul
(when required)
X
X
WEEKLY
MONTLY
YEARLY
OTHER
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
5 000 hour
5 000 hour
10 000 hour
- Maintenance process is crucial for NOVAtech chiller device to get optimum efficiency in terms of both operation and energy efficiency.
- Only the service received from authorized and qualified personnel can ensure the reliable and long-lasting operation of the device.
- Check the name of the refrigerant gas in the system on the device label, do not charge any other refrigerant without consulting ITECH.
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FORM NUMBER: 500_FRM.025
REV. NO:02 REV.DATE : 22.03.2018
34