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1、 Structural principle
This machine consists of six parts: a water air heat exchanger, an ion exchanger, a high-level expansion water tank, a pump unit, pipelines, and electrical control. The working principle is shown in the flowchart LSF-200 * 6: The heat carrying pure water input from the host enters the machine through pipe A, and is pressurized by a pure water pump through an air-water separator before entering the air-water heat exchanger to transfer heat to the strong flow air and take it away, becoming cooling pure water. It is then input into the load (frequency converter), the cooling water channel absorbs heat, and enters the machine again through the input pipeline. This forms a closed loop cooling circuit in a repetitive manner.
The water quality of pure water continuously decreases due to various factors during the circulation process. Therefore, an ion exchanger bypass is installed in the main circuit to continuously supplement high-purity water to maintain the water purity of the circuit. The ion exchanger is equipped with long-lasting maintenance free ion exchange resin, with a normal service life of over 3 years.
The water air heat exchanger of this machine is composed of a rolled fin heat exchanger and a low-noise axial flow fan. The finned heat exchange tube is composed of stainless steel cooling tubes and aluminum finned tubes, and is formed in one go using the integral rolling process, which has a high thermal conductivity; The pure water carrying heat flows through the cooling tube and transfers the heat to the forced flowing air (wind) through the surface of the fins. The fan is a low-noise axial flow type.
Pure water power adopts a shielded pump design, with a single configuration power of 15KW; Install stainless steel quick release butterfly valves at the inlet and outlet of the pump for quick and convenient replacement of the water pump; The water pump is fully sealed, with no motor fan or exposed bearings, and the noise level is less than 60dB.
The electrical secondary control of this machine is equipped with: the water pump is equipped with short circuit, phase loss, and locked rotor protection, and the pure water temperature, water pressure, water quality, water level reading display or alarm sound and light indication and protection system. The signal lights and operation keys display the start and stop conditions of the fan and electric heater. All indication alarm contents are output to the main control room for centralized processing through the "external supply contact" terminal.
The machine is equipped with a nitrogen filling buffer water tank:
The buffer tank can buffer the capacity changes of cooling water caused by temperature changes. When the volume of pure water in the circuit decreases due to leakage or other reasons, the buffer tank supplements the circuit with its own pressure to maintain the circuit always filled with pure water.
A nitrogen stabilization system is connected in series on the water treatment circuit, consisting of a buffer tank, solenoid valve, nitrogen cylinder, and water replenishment device. The top of the cooling medium buffer tank is filled with high-purity nitrogen gas at a stable pressure. When the cooling medium is lost due to a small amount of leakage or electrolysis, the nitrogen gas automatically expands and presses the cooling medium into the circulation pipeline system to maintain a constant pressure in the pipeline and fill the cooling medium.
Nitrogen sealing isolates the cooling medium from air and plays an important role in stabilizing the conductivity and dissolved oxygen of the cooling medium in the pipeline.
Deionized water treatment circuit:
The deionized water treatment circuit operates as a bypass to the main circulation circuit, mainly composed of a precision mixed bed ion exchanger and related accessories. It purifies some of the cooling medium in the main circulation circuit and continuously removes ions from the cooling medium to achieve the goal of maintaining high electrical resistivity for a long time. The ion exchange resin adopts imported nuclear grade non regenerated resin, with large adsorption capacity, high temperature resistance, high flow rate, and is dedicated to the removal of trace ions. The processing capacity of the deionized water circuit is set to the set value during normal operation of the equipment. If there are no special sources of pollution and the quality of the make-up water is ≥ 100K Ω· cm, the cycle for replacing the resin in the system is more than 3 years.
The deionized water circuit is designed to prevent resin crystal particles from entering the main water circuit due to water backflow.
Electric heater:
Placed on the inlet side of the main circulating cooling water circuit cooler, it is used to regulate the temperature of the cooling water when the valve body is shut down for a long time and restarted during extremely low temperature seasons, in order to avoid the cooling water temperature being too low. During the operation of the electric heater, the main cooling circuit is kept shut down normally to ensure safety.
Cooling medium and pipeline:
Due to operating under high voltage conditions, this system requires high-purity water as the cooling medium to avoid the presence of impurity ions in the cooling medium that may cause leakage current between components. To maintain the high purity of the medium, pharmaceutical grade 304 or higher stainless steel sanitary pipes are used for the circulation pipelines.
The highest position of the pipeline system is equipped with a specially designed automatic exhaust valve, which can automatically and effectively separate gas and water and has exhaust function to ensure minimal liquid leakage. For the convenience of inspection, maintenance, and upkeep, the lowest position of the water cooling system pipeline is equipped with a drain outlet, emergency drain outlet, etc., and sufficient maintenance space is reserved.
2、 Technical parameters
1. Rated cooling capacity: 1200 KW
2. Water supply capacity (Q-H): 100 T/H 0.32 MPa
3. Water supply temperature: ≤ 45 ℃
4. Pure water resistivity: ≥ 5 M Ω. cm
5. Design inlet air temperature: ≤ 39 ℃
6. Each heat exchange and cooling capacity: 200 KW
7. Number of heat exchangers: 6 pieces
8. External pipeline diameter: DN100
9. Whole machine electrical power: 87 KW
10. External dimensions:
Water air heat exchanger: L8920 × B3670 × H1800
Pump set: L1600 × B1600 × H2000
11. Weight:
Water air heat exchanger (per P pieces): 2000kg
Pump set: 1000kg
3、 Use
1. Pump installation: Prefabricate the machine base foundation according to the drawing dimensions (please refer to the "Reference Drawing for Cooler Foundation"), and install a floor drain or drainage ditch to discharge the discharged water during commissioning or maintenance
Installation of water air heat exchanger: When installing the heat exchanger, attention should be paid to the vertical placement. The inlet surface (finned tube surface) should face the dominant summer wind direction and be away from the building during the day. The horizontal placement of the inlet surface should be no less than the width of the inlet from the ground. There should be no flat obstacles within three meters of the upper part of the outlet to avoid affecting the inlet air volume or causing hot air recirculation and affecting the cooling effect.
2. Connect the pump unit, heat exchanger, and main unit of the cleaned corrosion-resistant pipeline into a closed circuit as required.
3. Connect the secondary signal connection between the electrical control box and the pump unit, and the signal terminal lead to the main control room. Connect the power inlet, water pump, fan motor, and heater power leads according to the terminal positions.
4. Cleaning and testing: Close the drain valve and the inlet and outlet valves of the ion exchanger, and open all other valves in the circuit. Inject clean tap water into the system circuit through the e-port, and adjust the outlet valve F12 to the slightly open position; Connect the power, turn on the water pump, adjust the pump direction, and adjust F12 to the required pressure position at the inlet of the main engine; Check the sealing condition of the entire circuit; Test and adjust the electrical control and protection contents of each fan and gear; Stop the machine and unscrew G1Connect the hose and circuit to the main unit, and close the drain valve after draining the remaining water. Inject pure water with a pressure of ≥ 0.1MPa into the system circuit through the e-port. After the pure water is filled, control F12, turn on the machine, and continue adding pure water until the water level stabilizes and meets the requirements. Stop adding water; Adjust valve F12 to bring the water pressure of the main engine to the specified value. Open the ion circuit valve and control F21 to slowly raise the water quality to the specified value before shutting down for later use.
5. Operation: Start the water pump according to the instructions, check that all parts are normal, and then put the main engine into operation. Turn on the fan and control the number of fan operations to stabilize the pure water temperature in the main circuit at the required value.
6. Shutdown: After receiving the shutdown command, press the stop button for the fan and water pump, disconnect the power switch, and the machine will exit operation.
If this machine is not used for a long time, the pure water should be drained completely; When the winter load host is shut down, it is even more important to pay attention to draining water to avoid freezing and cracking the pipes in the cold winter.
7. If frequent shutdowns are required during the winter freezing period, antifreeze coolant must be used; Taking -10 ℃ as an example, the ratio of antifreeze coolant is (volume ratio): pure water: 72%, ethylene glycol (industrial grade one): 28%.
4、 Maintenance and upkeep
After one year of continuous operation of this machine, a comprehensive maintenance and upkeep of all components should be carried out;
4.1 Water air heat exchanger:
a) Fin dirt removal: Disassemble the shield and motor, and use a high-pressure water gun or compressed air to repeatedly flush the fins up and down
Remove dirt and debris from the film;
b) Fan motor: Remove the fan blades, dismantle the fan blades, remove and extract the motor rotor, wash the bearings in gasoline, apply butter, and reinstall them; After cleaning, check the bearings by hand. If there is any abnormal sound, it indicates wear and should be replaced.
4.2 Water pump: The main maintenance of the main pump is to clean the bearings. If the mechanical seal is worn, it should be replaced. The water pump should not run dry without water. After flushing in an empty state, the exhaust plug must be unscrewed for exhaust. During operation, exhaust should also be carried out frequently to avoid burning the mechanical seal of the pump shaft. (Refer to the water pump user manual)
4.3 Ion exchange resin: The ionizer of this machine is equipped with maintenance free long-lasting ion exchange resin, which is generally used for more than 3 years. When it fails, it should be replaced with a new one.
4.4 Filter: The precision filter element of the water replenishment and separation circuit can be disassembled and washed. If it is severely worn, it should be removed and replaced with a new one.
4.5 Pipeline: Mainly check whether each sealing rubber component is aging and needs to be replaced.
4.6 Circuit: Please maintain and upkeep the intelligent components, touch screen, sensors, etc. of this machine according to the user manual; Relay components should be operated according to the "routine maintenance of machine tools and electrical appliances", with a focus on checking the tightness of screws, whether the contactor contacts have shifted or burned out, and checking the insulation to ground.
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