English

Index The chiller is CE conform; please find the CE lable on the

unit as showed:
1. Warranty
2. Safety
3. Functional Description
4. Receiving and Unpacking
5. Positioning the Chiller
6. Foundation
7. Connections
8. Process Water / Fluids
9. Waterquality
10. Process Oil / Fluids
11. Ambient temperature
12. Start up of the chiller
13. Maintanace / Check and Inspections
14. Design Charachteristics
15. Debug Table

1. Warranty 3. Functional Description

This warranty covers the material design and quality during The Chiller has been designed for the cooling and the control
the first 12 months starting from the delivery date. Within this of liquids in a closed circuit. The refrigerant circuit is
defined period our Company will either repair, or replace designed out of a heat exchanger (evaporator) in which the
(with ex works delivery) all parts which on the sole opinion of coolant evaporates, a compressor which sucks up the
the supplier, have caused quality problems which are not a evaporated fluid and compresses it into another heat
result of poor maintenance, inexperience of the operators, exchanger (condenser) in which the coolant condenses
faulty installation or failures which are caused because this (becomes liquid) and passing through the expansion device
instruction was not followed. This warranty does not include (thermostatic valve, capillary tube) to the evaporator. The
the expenses, travel hours and travel allowance related to temperature of the liquid to be cooled is controlled by the
our technicians in case their presence is required at the thermostat. Some safety devices as pressure switch and
customer's factory. These expenses will be totally invoiced thermostat, circuit fault indicators, are shown in the attached
as working hours. The customer shall not have the right to electrical diagram.
claim any refund from our Company for the time during which
the machine shall remain inactive, related to repairs. No
refund will be acknowledged for expenses, damages, either
direct or indirect, which are a result of the above. 4. Receiving and Unpacking
Sperate agreements with customers have to be agreed in For the operations of lifting and movement it is necessary to
written form may vary from this paragraph. use a fork lift truck with proper load capacity and with forks
longer than the base of the chiller. Avoid sudden movements
which can damage the framework and the internal
components. PFANNENBERG Std chiller (above 45Kg
2. Safety weight) are also provided with 4 eye bolts for lifting and
transportation; to be used for vertical loading/unloading only
General: these instructions have to be read by the installer
and personnel in charge for operation, before starting the
chiller.
All safety and security instructions given in this manual have
to be observed!
Only qualified personnel is allowed, to install and operate the
chiller and to do the maintenance work.
Non observance of the instructions may cause injuries and
will cancel the manufacturers liability for subsequent
damage.
National regulations on accident prevention, regulations of
the local power supply authorities as well as any specific
safety instructions for chiller must be observed. Check after the final positioning of the chiller the internal
The safety of the unit is only guaranteed, if it is used as connections to avoid damage during operation.
intended

5. Positioning the Chiller

Place the Chiller in an area shielded from any possible
manufacturing residuals (shavings, dust, etc.) and well-
ventilated, away from heat sources and direct influence of
sun light ; if possible, near the user system, in order to avoid
load losses along the hydraulic connection pipes. Use the
adjustable feet to level off the cooling unit.

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The customer has to place a suitable room at disposal, as power cable. Make sure the system is adequately earthed.
shown in the figure: Check that the voltage and frequency of the power supply
correspond to the specifications on the unit’s data plate
and/or enclosed electrical plan.

Room minimum dimensions

CAUTION!: For standard unit the outdoor installation is

absolutely forbidden, even if under a roof.
Only special designed outdoor units can be used in outdoor
installation
For regular maintenance or adjustment, the chiller shall be
located between 0,3 m and 1,0 m above the servicing level Example of Electric connection plate

CAUTION!: In case units that can work with different

6. Foundation voltages (400V or 460V), connect the transformer of the
auxiliary circuit located inside the e-box in the right way.
PFANNENBERG chillers should be set on a concrete slab.
The slab should extend a minimum of 30cm (12 inches) Voltage Limitations:
beyond the perimeter of the chiller to prevent damage from
lawn maintenance equipment, etc. The chiller should be level
and properly anchored. • Unit Nameplate - 115V/60Hz/1Ph: 103V to 127V
• Unit Nameplate - 230V/50-60Hz/1Ph: 207V to 253V
• Unit Nameplate - 400V/50Hz/3Ph: 360V to 440V
7. Connections • Unit Nameplate - 460V/60Hz/3Ph: 414V to 506V
Warning! Hydraulic connections are the first ones to be
assembeled during installing operation, to be followed by
electric connections. 8. Process Water / Fluids
Hydraulic connections. For the hydraulic connection please
PFANNENBERG chillers should be filled to the proper level
refer to the enclosed hydraulic plan. The flow rate and the
with an inhibited glycol designed for Industrial chillers
fluid circulation direction must be respected during
systems. Do not use automotive antifreeze! The inhibitors
connection in accordance with INLET-OUTLET identification
used in automotive antifreeze can break down quickly and
plates.
accelerate the degradation of the coolant base (glycol); as
well as promote corrosion in a system. Silicates used in
automotive antifreeze coat heat exchangers, resulting in
reduced heat transfer. Also, silicates can gel causing fouling
and plugging of a system.

The ratio of inhibited glycol to water should be adequate to

prevent freezing at the lowest ambient temperature. Check
the level with all lines filled. The glycol mixture should be
checked periodically (3 to 6 months) for proper
concentrations. When filling the system, always use a pre-
mixed solution in the proper ratio to maintain freeze and
corrosion protection. Distilled water is recommended
because many municipal water supplies contain large
amounts of chlorine, which can react unfavorably with glycol.

NOTE: If supply and return lines are overhead, the fluid

in the piping may drain back and overflow the chiller
reservoir if the chiller is shut down. This can be
Example of Hydraulic connection plate prevented by using a check valve in the supply line, and
either a solenoid valve on the return line.
CAUTION!: In case of unit with tank, please fill the tank
before connecting Hydraulic tubes.
Electric connections. The unit must be electrically
connected by the customer. Note, however, that electrical
installation must respect all valid safety standards. It’s
advisable to install a magnetic-thermal cutout upstream

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Corrosion protection: Water quality A (No water treatment necessary):

PFANNENBERG recommends that Glycol is also used as a Fresh water from the tap, free of contamination
rust inhibitor. The minimum percentage of glycol (in a mixture Ph-level:7-9
with water) recommended by some important glycol supplier Hardness: <5 °dH
(Clariant, Total, Dowfrost, etc..) is between 20% and 30%. Conduction: <50µS/cm
Chloride: <20 mg/l
CAUTION!: Please contact the Glycol supplier to know
the minimum percentage needed in order to use the Glycol Water quality B (Water treatment is recomemended):
as rust inhibitor
Fresh water from tap, free of contamination
Ph-level:7-8, 5
CAUTION!: All the typelabel of the STD Pfannenberg Hardness: <10 °dH
unit are provided with a percentage of glycol of 20% Conduction: <300µS/cm
Chloride: <50 mg/l
The percentages of glycol into the mixture is related to the
minimum working temperature of the mixture (that must be in
line with the minimum working set point of the unit, please Water quality C (Water treatment manditory):
see the technical data of the unit): Fresh water from tap, free of contamination
Ph-level:7-8,5
percentage Water temperature up to : Hardness: <20 °dH
Conduction: <500µS/cm
10% + 3 °C Chloride: <100 mg/l
15% 0 °C
20% - 3 °C 10. Process Oil / Fluids
25% - 6 °C
PFANNENBERG chillers (in the std oil version) are designed
30% -10 °C to work with the following oil viscositys:

CAUTION!: The greater the concentration of glycol the

lower the amount of heat rejection you will be able to get out • Fluids and oil’s with viscosity ranging between ISO
of the fluid. VG22 and ISO VG68 (*)

CAUTION!: The type of glycol (propylene or ethylene) CAUTION!: do not utilize oils with sulphur-base
must be in conformity with the Standard requested by the
application, please contact the Glycol supplier additives; the copper-made exchanger could be damaged (*)

CAUTION!: a suitable filtering system, for the oil to be

9. Waterquality cooled, has to be adopted, with filtration degree ranging from
60 to 90 mm (*).
To keep the hydraulic circuit correct and trouble-free, it is NB (*) should any doubt arise, consult PFANNENBERG
necessary, to check the water quality and if necessary, carry Technical Office.
out water treatment. The standard circuit of a water chiller is
a half open system, that means, part of the water
steams/evaporates out during operation. That means, that OIL CHILLER w/o pump
the concentration of chloride is getting higher and the system
water will cause corrosion on the installed components. Usually, the pumpless CHILLERS are inserted in a circuit
already provided with pump. Refer to instructions provided
When using water, please consider the following: by the system manufacturer and check that the flow rate and
pressure entering the REFRIGERATOR are compatible with
• Do not use deionized water. the values set down in the chapter of technical data

• Do not allow mechanical contamination to get in the OIL CHILLER with pump
water. Use water filters if this could be a problem.
Usually, the CHILLERS with pump are utilized to cool an
• Water hardness should not be too high. (see below) hydraulic system provided with reservoir; therefore, the filling
is directly carried out on the machine. Refer to the
• Watch for chemical contamination. If this is to become a instructions provided by the system manufacturer
problem, treat the water with passivators and/or
inhibitors.
11. Ambient temperature
• Do not allow biological, slime bacteria, and algae
When ambient temperatures are above 35 degrees C. (95
contamination. If this does happen, treat the water with
degrees F.) or below 10 degrees C. (50 degrees F.),
biocides.
PFANNENBERG should be consulted. High ambient
PFANNENBERG recommends that the properties of the temperatures reduce chiller capacity. Low ambient
water has to be checked in order to identify the quality temperatures require special controls. Special conditions
apply when temperatures drop below 0 degrees C. (32
degrees F.). Fluid heaters may be required to prevent

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freezing and to hold the fluid in the chiller reservoir at a Switch all circuit breakers to the “on” position. At this time the
constant temperature in order to reduce start-up delays while chiller should operate automatically according to the
the fluid warms up to operating temperature. controllers “set point values”. If necessary, set controller
according to customers temperature requirements. (Please
refer to the manual of the thermostat delivered with the unit)
12. Start up of the chiller
CAUTION!: WORK ON THE ELECTRICAL AND After installation, the REFRIGERATOR does not need
REFRIGERANT CIRCUITS MAY ONLY BE PERFORMED intervention by the Qualified Operator.
BY QUALIFIED PERSONEL.!!!!!!! Every calibration operation on thermostats, pressure switch
and whatever component of the refrigerating circuit, the
personnel of the Technical Servicing or the Refrigerator
• Turn main switch, control switch, all circuit breakers to Technician only is competent.
switches to the - 0 - (off) position.

• Check the internal hydraulical connection (clamps and For further information on chiller installation, start-up or
fittings) that may get loose during transportation troubleshooting please contact PFANNENEBERG

CLOSE LOOP CHILLER

• CHILLER with tank: Remove cap of filling connection
The difference between the Start up of an open loop and a
located at the top side of the chiller (external) or
close loop water chiller is the filling of the system.
reservoir top plate (internal). Fill reservoir with water-
PFANNENBERG units are equipped with a manual (or
glycol mixture until the maximum level is reached. (water
automatic on request) refill connection, Air discharge valve
quality and treatment should be established according
and Safety valve
to the application specifications)

• All water inlet and outlets connections should be fitted

and a visual inspection should be made.

• Main power feed and control interlock should be

established with customer’s equipment.

• CHILLER with pump: Purge pumps by loosening purging

screw that is located on the side of pump. Be advised
that the pump has been purged correctly when only
water is visible.

• CHILLER with pump: Main power switch and circuit

breaker for the pump (pumps) should be switched to the
on position. (all other circuit breakers should stay in the
off position) 1. Air valve
2. Safety valve
• CHILLER with pump: Main switch should be switched to 3. Refill
the - l - (on) position and the pump (pumps) should be
checked for the correct rotation. (Please note that there • Make sure that all the connection (hydraulical and
is an arrow located at the back part of the pump for Electrical) are done as explained above for the Std units
direction indication). Reverse two phases R-S-T on the
terminal board in case of incorrect rotation
• Connect the Refill line with a pump (external refilling
CAUTION!: The pump must not flat running or in inverse pump) in order to refill the system with the correct
direction; therefore the checking of the correct rotation must mixture (water/glycol, please see the section 8)
be quick
• Open the hand valve of the refill line and start the filling
• At this time a visual inspection of the hydraulical circuit by switching on the refilling pump
and all connections for leaks should be made..
• The pressure into the system after the refill must be
• CHILLER with tank: While water circuit is running make appr. 2 bar
sure proper water level is maintained and if necessary fill
reservoir to the proper level.
CAUTION!: The system is provided with a safety valve,
opening at 6 bar
• CHILLER with tank: After the water circuit has run for
approx. 5 minutes, switch off the main switch and check • Make sure that all the air goes out to the air valve
again the visual level of the tank; refill the tank in case of
need. • After the filling, close the hand valve of the Refill line

• CHILLER without pump: check the fan direction of • Start the system in the same way like described above
rotation (see the arrow on the fan case). Reverse two for the Std units
phases R-S-T on the terminal board in case of incorrect
rotation • After the water circuit of the unit has run for approx. 5
minutes, switch off the main switch and check again the
pressure of the system

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13. Maintanace / Check and Inspections
CAUTION! Before any maintenance intervention, not
needing the machine running, disconnect the supply voltage
and have a sign MAINTENANCE IN PROGRESS to be • Longer standstill of the chiller requires draining of the
posted to the general breaker tank and complete water circuit.

To carry out the tests and check program described here will • Check of the thermal charge of the chiller: the
extend the life of the equipment and avoid possible temperature and the delivery of the hydraulic circuit must
breakdowns. not exceed to the set limits of the unit

• If the chiller is equipped with a filter on the hydraulical

side, the filter has to be checked/cleaned monthly, or, if
• Check mechanical working of the compressor : the required in a shorter time interval
absence of metallic vibrations and a temperature
between +20°C and +70°C, measured on the
compressor head during running, show a regular
working of the compressor. 14. Design Charachteristics
• Inspection of the condenser to see if it is clean. The fins
of the condenser must not have any dust deposits or
Closed loop applications
residual products or sludges on their surface .
If we have a closed loop water circuit, under pressure,
• Check the operation of the fan. application, there is no problem placing the chiller above or
below the application.
• Check the electrical alarm systems and controls.
A closed loop water circuit is where there is no contact
• Check the filling of the tank (visual level). If the system is between the water and the air. Typically there is no tank in
filled with a glycol-mix, refill only with the same mix. Only the chiller. When there is a tank, it is under pressure. This
water will reduce the concentration of glycol. allows the water a place to expand and contract.

• The condenser must be cleaned in monthly intervals, or, Open loop applications
if required in shorter time intervals.
An open loop application is where there is some contact
• If the chiller is equipped with an air filter, the filter has to
between the air and the water. Our standard chillers, with
be changed/cleaned monthly, or, if required in a shorter
tanks, allow contact between air and water. Typically when
time interval
we cool a customer reservoir, the reservoir allows contact
between air and water.
In an open loop application, there is no problem placing the
chiller above the application.
There are some precautions we need to take when placing a
chiller below the application when we are in an open loop
application. There needs to be a check valve in the water
pipes on the outlet of the chiller. (A check valves allows
water to go out, but it does not allow it to come back.) There
also need to be an electrical solenoid valve placed on the
inlet of the water chiller. This valve needs to close when the
chiller is not running. These two valves will prevent water
from flowing back into the chiller, and overflowing out of the
tank

1. Air filter

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15. Debug Table
The information shown in this table is designed for the service staff at the factory. The faults that require the intervention
of a refrigeration engineer must be carried out only by specialized staff. Follow all electrical legislation when working on
the unit basaed on valid laws of the countries were the unit is placed.

Chiller
Problem Cause Possible corrective Action
The unit does not start No supply voltage Check the supply main voltage line
up Not working thermostat Inspect the connection, check and correct the parameter settings and if there
is no fault, replace the thermostat,
The compressor protector (KLIXON) Important: After the shut down of the compressor, the resetting time will
has switched off depending on the environment of the compressor: In a hot closed
environment it will be 2 hours, in ventilated 1 hour.
Note: The compressors are protected against high temperatures and
currents, with of an internal or external device (Klixon). The internal/external
device protects the compressor against the following situations:
• overheating due to an inadequate cooling of the compressor motor.
• Blocked compressor due to a high temperature of the motor or a high
current.
• Loose connections which may cause high currents
It works, but does not There is not enough gas in the Service by a refrigeration engineer
cool equipment
Faulty thermostatic valve Service by a refrigeration engineer
Too high heat load Possible wrong application, to be checked with our staff
Refrigerant Cycle is not working
Problem Cause Possible corrective Action
Switching of the double The unit works for short periods, it Service by a refrigeration engineer
pressure switch (low stops and starts again after a while.
pressure side) The causes are:
• Low gas level in the equipment
• Outlet line of the compressor is
blocked and more in detail:
satured dehydrating filter,
blocked thermostatic valve.
Switching of the double The unit does not work.
pressure switch (high The causes are:
pressure side)
• Dirty condenser Clean the condenser with compressed air if it is full of dust, or use proper
solvents suitable to remove sludges.
• The fan is broken Replace the fan
• Too high ambient temperature Check that the chiller is located in a place that can guarantee suitable
ventilation of the refrigerating unit. Check also that the ambient temperature
does not exceed +40°C.
Note: after solving the cause of
the fault, start the chiller by
pressing the reset button (RESET)
located on the external body of the
pressure switch itself (see the
picture)

Compressor
Problem Cause Possible corrective Action
The compressor works continuously and the chiller can’t control the liquid temperature:
- too low temperature of the liquid
- too high temperature of the liquid
Too low temperature Broken thermostat (contact blocked) Replace the thermostat
Broken thermostat Replace the thermostat
Too high temperature Not enough Freon in the unit Please ask for the service by a refrigeration engineer
Too high heat load Possible wrong application, to be checked with our staff

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