Conair | 0.25 to 1.5 ton | User guide | Conair 0.25 to 1.5 ton User guide

Portable Chillers
Series 1 Water-Cooled (W1) and
Air-Cooled (A1) Models with PLC Control
Installation
Operation
Maintenance
Troubleshooting
Instant Access
Parts and Service
(800) 458-1960
(814) 437-6861
www.conairnet.com
The Conair Group, Inc.
One Conair Drive
Pittsburgh, PA 15202
Phone: (412) 312-6000
Fax: (412) 312-6227
UGH017/0500
Please record your
equipment’s model and
serial number(s) and
the date you received it
in the spaces provided.
It’s a good idea to record the model and serial number(s) of
your equipment and the date you received it in the User
Guide. Our service department uses this information, along
with the manual number, to provide help for the specific
equipment you installed.
Please keep this User Guide and all manuals, engineering
prints and parts lists together for documentation of your
equipment.
Date:
Manual Number:
UGH017/0500
Serial number(s):
Model number(s):
Power specifications:
Amps
Volts
Phase
Cycle
DISCLAIMER: The Conair Group, Inc., shall not be liable for errors
contained in this User Guide or for incidental, consequential damages in connection with the furnishing, performance or use of this
information. Conair makes no warranty of any kind with regard to
this information, including, but not limited to the implied warranties
of merchantability and fitness for a particular purpose.
Copyright 2000
THE CONAIR GROUP, INC.
All rights reserved
INTRODUCTION . . . . . . . . . . . . . . . . . . .1-1
Purpose of the User Guide . . . . . . . . . . . . . . . . . . . . . . . . .1-2
How the Guide is Organized . . . . . . . . . . . . . . . . . . . . . . .1-2
Your Responsibilities as a User . . . . . . . . . . . . . . . . . . . . .1-2
ATTENTION: Read this so no one gets hurt . . . . . . . . . . .1-3
TABLE OF
CONTENTS
DESCRIPTION . . . . . . . . . . . . . . . . . . . .2-1
What is the Portable Chiller? . . . . . . . . . . . . . . . . . . . . . . .2-2
Typical Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-3
Limitations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-3
How it Works: Water-cooled Portable Chiller . . . . . . . . . .2-4
How it Works: Air-cooled Portable Chiller . . . . . . . . . . . .2-6
Portable Chiller Features . . . . . . . . . . . . . . . . . . . . . . . . . .2-8
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-10
Pump Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-12
INSTALLATION . . . . . . . . . . . . . . . . . . . .3-1
Unpacking the Boxes . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2
Warnings and Cautions . . . . . . . . . . . . . . . . . . . . . . . . . . .3-3
Preparing for Installation . . . . . . . . . . . . . . . . . . . . . . . . . .3-4
Making Process Plumbing Connections . . . . . . . . . . . . . . .3-5
Filling the Chiller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-6
Checking Refrigerant Charge . . . . . . . . . . . . . . . . . . . . . . .3-8
Connecting the Main Power Source . . . . . . . . . . . . . . . . . .3-9
Checking Electrical Connections . . . . . . . . . . . . . . . . . . .3-10
Initially Starting the Chiller . . . . . . . . . . . . . . . . . . . . . . .3-10
Checking for Leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-12
Connecting the Remote Control . . . . . . . . . . . . . . . . . . . .3-13
Stopping the Chiller . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-13
OPERATION . . . . . . . . . . . . . . . . . . . . . .4-1
PLC Control Features . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2
Before Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-3
Powering Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-4
Running/Stopping the Chiller . . . . . . . . . . . . . . . . . . . . . . .4-5
Viewing Chiller Status . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-6
Programming Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-8
Changing Setpoint Temperature . . . . . . . . . . . . . . . . . . . .4-9
Resetting PID Settings . . . . . . . . . . . . . . . . . . . . . . . . . . .4-10
Changing High Temperature Deviation . . . . . . . . . . . . . .4-11
Setting Percent Glycol . . . . . . . . . . . . . . . . . . . . . . . . . . .4-12
Setting Fan Setpoints . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-14
Setting Auto Tune Mode . . . . . . . . . . . . . . . . . . . . . . . . .4-16
Manually Starting/Stopping the Pump . . . . . . . . . . . . . . .4-18
UGH017/0500
Series 1 Portable Chillers, PLC Control
i
TABLE OF
CONTENTS
MAINTENANCE . . . . . . . . . . . . . . . . . . . .5-1
Maintenance Features . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-2
Warnings and Cautions . . . . . . . . . . . . . . . . . . . . . . . . . . .5-3
Preventative Maintenance Schedule . . . . . . . . . . . . . . . . . .5-4
Entering Maintenance Screens . . . . . . . . . . . . . . . . . . . . . .5-6
Checking Electrical Connections . . . . . . . . . . . . . . . . . . . .5-8
Cleaning the Evaporator or Water-cooled Condenser . . . . .5-9
Cleaning the Air-cooled Condenser . . . . . . . . . . . . . . . . .5-10
Checking the Refrigerant Charge . . . . . . . . . . . . . . . . . . .5-11
Checking Reservoir Level . . . . . . . . . . . . . . . . . . . . . . . .5-12
TROUBLESHOOTING . . . . . . . . . . . . . . . .6-1
Before Beginning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-2
A Few Words of Caution . . . . . . . . . . . . . . . . . . . . . . . . . .6-3
Identify the Cause of a Problem . . . . . . . . . . . . . . . . . . . . .6-3
Answering Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-4
Control Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-6
Alarm Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-8
Checking and Replacing Switches . . . . . . . . . . . . . . . . . .6-16
Checking the Pressure Transducer . . . . . . . . . . . . . . . . . .6-17
Checking the Temperature Transmitter and RTD . . . . . . .6-18
Replacing the RTD . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-20
Replacing the Temperature Transmitter . . . . . . . . . . . . . .6-21
Removing Pump Components . . . . . . . . . . . . . . . . . . . . .5-22
Replacing Overload Modules . . . . . . . . . . . . . . . . . . . . . .6-23
Replacing Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-24
Replacing the Contactor . . . . . . . . . . . . . . . . . . . . . . . . . .6-25
Replacing the PLC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-26
APPENDIX . . . . . . . . . . . . . . . . . . . . . .A-1
Customer Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-1
Maintenance Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-1
Pressure Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-1
PARTS
ii
AND
DIAGRAMS . . . . . . . . . . . .P/D-1
Series 1 Portable Chillers, PLC Control
UGH017/0500
INTRODUCTION
● Purpose of the User Guide . . . .1-2
● How the Guide is Organized . . .1-2
● Your responsibilities as a user .1-2
● ATTENTION: Read this so
no one gets hurt . . . . . . . . . . .1-3
Series 1 Portable Chillers, PLC Control
UGH017/0500
1-1
PURPOSE OF
THE USER
GUIDE
This User Guide describes Conair’s Series 1 Water-cooled and
Air-cooled Portable Chillers and explains step-by-step how to
install, operate, maintain and repair this equipment.
HOW THE
GUIDE IS
ORGANIZED
Symbols have been used to help organize the User Guide and
call your attention to important information regarding safe
installation and operation.
YOUR
RESPONSIBILITY
AS A USER
Before installing this product, please take a few moments to
read the User Guide and review the diagrams and safety information in the instruction packet. You also should review manuals covering associated equipment in your system. This
review won’t take long, and it could save you valuable installation and operating time later.
Symbols within triangles warn of conditions that could
be hazardous to users or could damage equipment.
Read and take precautions before proceeding.
1
Numbers within shaded squares indicate tasks or steps
to be performed by the user.
◆
A diamond indicates the equipment’s response to an
action performed by the user.
❒
●
An open box marks items in a checklist.
A shaded circle marks items in a list.
You must be familiar with all safety procedures concerning
installation, operation and maintenance of this equipment.
Responsible safety procedures include:
● Thorough review of this User Guide, paying particular
attention to hazard warnings, appendices and related diagrams.
● Thorough review of the equipment itself, with careful
attention to voltage sources, intended use and warning
labels.
● Thorough review of instruction manuals for associated
equipment.
● Step-by-step adherence to instructions outlined in this
User Guide.
1-2
INTRODUCTION
Series 1 Portable Chillers, PLC Control
UGH017/0500
We design equipment with the user’s safety in mind. You can
avoid the potential hazards identified on this machine by following the procedures outlined below and elsewhere in the
User Guide.
ATTENTION:
READ THIS
SO NO
ONE GETS HURT
WARNING: Improper installation, operation, or servicing may result in equipment damage or personal injury.
This equipment should only be installed, adjusted, and serviced by qualified technical personnel who are familiar with the construction, operation, and potential hazards of this type of
machine.
All wiring, disconnects and fuses should be
installed by qualified electrical technicians in
accordance with electrical codes in your region.
Always maintain a safe ground. Do not operate
the equipment at power levels other than what
is specified on the machine serial tag and data
plate.
WARNING: Electrical hazard
Before performing any work on this item, disconnect and lock out electrical power sources to
prevent injury from unexpected energization or
startup.
CAUTION: Hot Surfaces
Always protect yourself from hot surfaces when
working on the Portable Chiller, especially when
working on or around the compressor and condenser. These devices can reach up to 160 °F
(71 °C). Allow these devices to cool before performing any maintenance or troubleshooting.
CAUTION: Ventilation hazard
The unit requires a clean and well ventilated
operating environment. Do not place anything
on top of the unit while operating. Units with
fans require unrestricted outlet air flow.
Water-cooled units require a minimum of one
foot clearance around the perimeter for serviceability. Air-cooled units require a minimum of two
feet clearance around the perimeter for serviceability and proper air flow.
UGH017/0500
Series 1 Portable Chillers, PLC Control
INTRODUCTION
1-3
DESCRIPTION
● What is the Portable Chiller? . . .2-2
● Typical Applications . . . . . . . . . .2-3
● Limitations . . . . . . . . . . . . . . . . .2-3
● How it Works: Water-cooled
Portable Chiller . . . . . . . . . . .2-4
● How it Works: Air-cooled
Portable Chiller . . . . . . . . . . .2-6
● Portable Chiller Features . . . . . .2-8
● Specifications . . . . . . . . . . . . .2-10
● Pump Curves . . . . . . . . . . . . . .2-12
Series 1 Portable Chillers, PLC Control
UGH017/0500
2-1
WHAT IS THE
PORTABLE
CHILLER?
The Conair Series 1 Portable Chillers provide self-contained
sources of chilled water and are available in either water- or
air-cooled models. Ranging in size from 1.5 Hp to 13 Hp in
the air-cooled configuration and 1.5 Hp to 15 Hp in the watercooled design [approximate capacities of 1.5 tons of refrigeration to 15 tons of refrigeration]. Pump selections are available
to match most process flow and pressure requirements.
The normal temperature range of discharge chilled water is
20 °F (7 °C) to 70 °F (21 °C). For applications requiring temperatures of 40 °F (4 °C) and lower, mix glycol with the
water to the correct percentage.
The Air-cooled Portable Chiller A1 Models and Water-cooled
Portable Chiller W1 Models are designed to provide chilled
fluid for industrial applications requiring 24-hour-a-day performance. Units are totally self-contained for easy, economical
installation. All parts wetted by the process are non-ferrous.
To operate, simply connect the power source, process piping
and fill with water or with industrial grade ethylene glycol or
propylene glycol (but not automotive antifreeze).
These chillers are ideal for machine-side cooling to maintain
process temperatures in an injection molding machine or
extruder and wherever you need a small, portable cooling unit.
Nominal capacities range from 1.44 to 14.68 tons for the
water-cooled models and from 1.18 to 10.95 tons for the aircooled models. Capacities are based on standard pump sizes
and delivering 50 °F (10 °C) water.
Operation of these units differ only in the medium used to
remove heat from the refrigerant in the condensers. Watercooled models use 85 °F (29 °C) or lower cooling water from
a tower, well, or city service; air-cooled models use 95 °F
(35 °C) maximum ambient air.
Choose Water-cooled Portable Chillers where tower water or
another inexpensive water source is available. Choose Aircooled models for maximum portability of the unit. Watercooled models are equipped with brazed plate or tube-in-tube
condensers. Air-cooled models use aluminum-fin, copper-tube
condensers.
All standard voltages are available.
2-2
DESCRIPTION
Series 1 Portable Chillers, PLC Control
UGH017/0500
The Conair A1 and W1 Portable Chillers can be used anywhere a reliable source of process cooling water - with stable
temperature control - is required.
TYPICAL
APPLICATIONS
These portable chillers are available for cooling injection
molding, blow molding, thermoforming, extrusion, air compressors, metal plating, anodizing, degreasing, heatset/web
offset printing presses, and dryer after-coolers.
Roll the air-cooled condenser models next to the heat source
connect it and plug it in. They can operate almost anywhere.
The water-cooled condenser models require a source of condenser water. Normally used in conjunction with a recirculating evaporative cooling tower system, the units have slightly
better operating energy efficiencies.
Conair Series 1 Portable Chillers are designed to provide
chilled water for industrial applications requiring 24-hour-aday performance. Units are self-contained and easy to install
and maintain. Choose the Conair Series 1 Portable Chillers
based on the cooling load and the capacity of the unit. Pick
your Conair Series 1 Portable Chillers based on:
LIMITATIONS
● Cooling load
Choose a portable chiller that has 20% more capacity than
the process load.
● Location
Choose a water-cooled model if the unit will be located in
an air-conditioned area and a source of condenser water is
readily available (i.e. cooling tower water). Do not locate
either portable chiller model outside unless the unit is
specially modified.
● Temperature
The portable chiller has a standard setpoint temperature
range of 20 °F (7 °C) to 70 °F (21°C).
Use this information as a general guide. Consult your Conair
representative for assistance when choosing a Conair Portable
Chiller.
UGH017/0500
Series 1 Portable Chillers, PLC Control
DESCRIPTION
2-3
Process circulation
HOW IT WORKS:
WATER-COOLED
PORTABLE
CHILLER
1
Hot fluid from the
process enters the
chiller through the From
Process valve into the
pump reservoir.
3
Fluid is chilled in the
evaporator and exits
through the To Process
valve and tube, returning to
the process.
2-4
DESCRIPTION
2
Pump draws water
from pump reservoir
and moves it through the
strainer and flow switch to
the evaporator.
Series 1 Portable Chillers, PLC Control
UGH017/0500
Refrigerant circulation
4 The liquid refrigerant
leaves the accumulator, passing through the
thermal expansion valve,
where it expands and
cools.
HOW IT WORKS:
WATER-COOLED
high pressure vapor travels from
3 The
the compressor through the coiled
CONT’D
condenser (where it is condensed into a
liquid) and is stored in the accumulator.
refrigerant
2 Vaporized
travels from evaporator to the compressor,
where the low pressure
vapor is compressed into
a high pressure vapor.
5
The evaporator extracts heat
1 from
the process fluid, caus-
Cooled refrigerant is metered
back into the exaporator for
the cycle to begin again.
ing the refrigerant to vaporize
(evaporate) into a gas.
UGH017/0500
Series 1 Portable Chillers, PLC Control
DESCRIPTION
2-5
Process circulation
HOW IT WORKS:
AIR-COOLED
PORTABLE
CHILLER
1
Hot fluid from the
process enters the
chiller through the From
Process valve into the
pump reservoir.
is chilled in the
3 Fluid
evaporator and exits
through the To Process
valve and tube, returning to
the process.
2-6
DESCRIPTION
Pump draws fluid
from pump reservoir
and moves it through the
strainer and flow switch to
the evaporator.
2
Series 1 Portable Chillers, PLC Control
UGH017/0500
Refrigerant circulation
HOW IT WORKS:
AIR-COOLED
4
CONT’D
The liquid refrigerant
leaves the accumulator,
passing through the thermal expansion valve,
where it expands and
cools.
3
The high pressure vapor
travels from the compressor
through the condenser (where
fans cool vapor into a liquid)
and liquid is stored in the
accumulator.
refrigerant
2 Vaporized
travels from evaporator to the compressor,
where the low pressure
vapor is compressed into
a high pressure vapor.
1
The evaporator extracts heat
from the process fluid, causing the refrigerant to vaporize
(evaporate) into a gas.
UGH017/0500
5
Cooled refrigerant is metered
back into the exaporator for
the cycle to begin again.
Series 1 Portable Chillers, PLC Control
DESCRIPTION
2-7
PORTABLE
CHILLER
FEATURES
Water-cooled Models
Condenser
Relief valve
acts as a safety
device for refrigerant pressure.
condenses the refrigerant from a high
pressure vapor into a
high pressure liquid.
Compressor
compresses the refrigerant from a low pressure vapor into a high
pressure vapor.
Hot Gas Bypass valve
balances the load on the
chiller to meet the needs of
the process.
Liquid line solenoid
valve
pumps down refrigerant
to the receiver.
Receiver
stores the liquid refrigerant.
Filter dryer
Temperature transmitter electrical box
cleans and dries the refrigerant.
transmits temperature
signals to the control
TX valve
Evaporator
regulates refrigerant flow
cools the process fluid
Process pump
From Process
connection
circulates process fluid
through the chiller.
Pump reservoir
To Process connection
stores process fluid. View fluid
level on water level gauge
Options include:
● 60 Hz process pump with:
1 1/2 Hp for W1-1.5, W1-2
2 Hp for W1-3, W1-4
3 Hp for W1-5, W1-7.5, W1-10, W1-15
● To Process and From Process valves
● Process bypass line and valve
● No reservoir/pump
● No reservoir
● Auto fill reservoir (for non-glycol systems)
● Condenser water differential pressure switch (W1-7.5 to
W1-15 only)
● Visual alarm
● Audible alarm
● Remote/redundant hand control with 30 ft. cable
● Remote/redundant hand control with 50 ft. cable
● UL labeled controls
2-8
DESCRIPTION
Series 1 Portable Chillers, PLC Control
UGH017/0500
Air-cooled Models
Condenser
compresses the refrigerant
from a high pressure vapor
into a high pressure liquid.
PORTABLE
CHILLER
FEATURES
Fans
circulate air across the condenser to cool refrigerant
Compressor
compresses the refrigerant from a low pressure
vapor into a high pressure vapor.
Hot Gas Bypass valve
balances the load on the
chiller to meet the needs of
the process.
Temperature transmitter electrical box
Receiver
stores the liquid refrigerant.
transmits temperature
signals to the control
Filter dryer
Liquid line solenoid
valve
cleans and dries the refrigerant.
pumps down refrigerant
to the receiver.
Evaporator
cools the process fluid
TX valve
From Process
connection
regulates refrigerant flow
To Process connection
Process pump
Pump reservoir
stores process fluid. View fluid
level on water level gauge
circulates process fluid
through the chiller.
Options include:
● 60 Hz process pump with:
1 1/2 Hp for A1-1.5, A1-2.25
2 Hp for A1-3.25, A1-4
3 Hp for A1-5, A1-7.5, A1-10, A1-13
● To Process and From Process valves
● Process bypass line and valve
● Condenser air filters
● No reservoir/pump
● No reservoir
● Auto fill reservoir (for non-glycol systems)
● Visual alarm
● Audible alarm
● Remote/redundant hand control with 30 ft. cable
● Remote/redundant hand control with 50 ft. cable
● UL labeled controls
UGH017/0500
Series 1 Portable Chillers, PLC Control
DESCRIPTION
2-9
Water-cooled Models
SPECIFICATIONS
side
front
back
F
A
10.5 {267}
D
E
5.5 {140}
10 {254}
C
B
MODEL
Performance characteristics
Capacity✝, tons
Compressor Hp {kW}
Pump Hp {kW}
60 Hz
50 Hz
Chilled water flow‡, gpm {lpm}
Chilled water pressure§, psi {bar}
Reservoir capacity, gal {l}
Condenser water flow, gpm {lpm}
Dimensions in {mm}
A-Height
B-Width
C-Length
D-Height to Condenser Out
E-Height to Condenser In
F-Distance to Valve
Weight lb {kg}
Installed
Shipped
Utility requirements
Process connections, in
Condenser water, in
Power consumption, amps
230V/3 phase/60hz*
220V/3 phase/50hz
460V/3 phase/60hz*
575V/3 phase/60hz*
9 {229}
W1-1.5
W1-2
W1-3
W1-4
W1-5
W1-7.5
W1-10
W1-15
1.44
1.5 {1.1}
1.93
2 {1.5}
3.23
3 {2.2}
4.44
4 {3}
5.00
5 {3.7}
7.09
7.5 {5.6}
10.22
10 {7.5}
14.68
15 {11}
0.75 {0.6}
1.5 {1.1}
6.9 {25.1}
27.8 {1.9}
8.0 {30.3}
5.0 {18.9}
0.75 {0.6}
1.5 {1.1}
4.6 {17.4}
29.9 {2.1}
15 {57}
6.4 {24.2}
1.5 {1.1}
2 {1.5}
12.0 {45.4}
41.6 {2.9}
15 {57}
16.7 {63.2}
1.5 {1.1}
2 {1.5}
17.0 {64.3}
34.8 {2.4}
25 {95}
24.1 {91.2}
49 {1245}
34 {864}
39.5 {1003}
37 {940}
38.5 {978}
31 {787}
32.5 {826}
4 {102}
420 {190}
550 {249}
1 {.8}
1 {0.8}
1.5 {1.1}
2 {1.5}
7.8 {29.5} 10.7 {40.5}
32.9 {2.3} 31.8 {2.2}
15 {57}
15 {57}
10.3 {39.0} 14.2 {53.7}
38.5 {978}
32.5 {826}
585 {265}
755 {342}
585 {265}
755 {342}
49 {1245}
34 {864}
45.5 {1156}
38.5 {978}
32.5 {826}
840 {381}
1010 {458}
38 {965}
32 {813}
41.3 {1049}
35 {889}
4.5 {114}
840 {381}
1010 {458}
1080 {490}
1250 {567}
1
1
run
9.5
13.1
4.5
3.6
full
15.3
19.1
6.9
5.5
run
10.2
13.8
4.9
3.9
full
15.6
19.4
7.1
5.7
run
15.1
17.8
7.3
5.8
full
24.4
27.5
11.1
8.9
run
18.7
22.5
9.1
7.3
full
29.4
33.6
13.3
10.7
run
22.5
24.3
10.9
8.7
full
36.3
38.6
16.4
13.1
run
29.2
31.3
14.2
11.4
full
44.7
47.4
20.2
16.2
1.5 {1.1}
2 {1.5}
2 {1.5}
2 {1.5}
24.5 {92.7} 35.2 {133.2}
29.3 {2.0}
32.3 {2.2}
25 {95}
25 {95}
31.7 {120} 45.4 {172}
61 {1549}
34 {864}
55 {1397}
41.3 {1049 41.3 {1049}
35 {889}
35 {889}
1090 {494}
1260 {572}
1.5
1.5
run
35.0
37.4
17.1
13.7
full
56.0
59.1
25.3
20.2
1095 {497}
1265 {574}
run
44.8
46.8
22.0
17.6
full
79.0
82.1
35.7
28.5
SPECIFICATION NOTES
✝ Based on 50 °F (10 °C) water temperature (100% water) leaving the chiller, standard pump selections, 85 °F (27 °C) condenser water supply
@ 25 psi minimum, for the 60 Hz units. For the 50 Hz units, multiply the capacity by 0.8 Consult factory for other conditions. Capacity ratings
are (+-) 5% based on compressor manufacturer’s ratings and are subject to change without notice.
‡ Based on 50° F (10 °C) water temperature leaving the chiller and 60 °F (16 °C) water temperature returning to the chiller (except W1-1.5
which has 55 °F (13 °C) water temperature returning to the chiller).
§ Pressure at pump discharge. See Pressure Tables in the Appendix for evaporator and condenser pressure drops.
* Optional
2-10
DESCRIPTION
Series 1 Portable Chillers, PLC Control
UGH017/0500
Air-cooled Models
SPECIFICATIONS
front
back
side
A
10.5 {267}
5.5 {140}
MODEL
Performance characteristics
Capacity✝, tons
Compressor Hp {kW}
Pump Hp {kW}
60 Hz
50 Hz
Chilled water flow‡, gpm {lpm}
Chilled water pressure§, psi {bar}
Reservoir capacity, gal {l}
Condenser Fans
Condenser fan power, Hp {kW}
Condenser air flow,
ft3/min {lpm}
Dimensions in {mm}
A-Height
B-Width
C-Length
Weight lb {kg}
Installed
Shipped
Utility requirements
Process connections, in
Power consumption, amps
230V/3 phase/60hz*
220V/3 phase/50hz*
460V/3 phase/60hz
400v/3 phase/50hz*
575V/3 phase/60hz*
10 {254}
C
B
9 {229}
A1-1.5
A1-2.25
A1-3.25
A1-4
A1-5
A1-7.5
A1-10
A1-13
1.18
1.5 {1.1}
1.79
2.25 {1.7}
2.77
3.25 {2.4}
3.62
4 {3}
4.27
5 {3.7}
6.06
7.5 {5.6}
8.75
10 {7.5}
10.95
13 {9.7}
0.75 {0.6}
1.5 {1.1}
5.7 {21.6}
29.6 {2.0}
8.8 {33.3}
1
0.17 {0.13}
1050
{29,732}
0.75 {0.6}
1.5 {1.1}
8.6 {32.6}
28.5 {2.0}
15 {57}
2
0.17 {0.13}
1704
{48,250}
1 {.8}
1.5 {1.1}
6.7 {25.4}
35.9 {2.5}
15 {57}
2
0.17 {0.13}
2420
{68,525}
1 {0.8}
2 {1.5}
8.7 {32.9}
33.9 {2.3}
15 {57}
2
0.25 {0.19}
4237
{119,975}
1.5 {1.1}
2 {1.5}
10.2 {38.6}
42.4 {2.9}
15 {57}
2
0.25 {0.19}
4237
{119,975}
1.5 {1.1}
2 {1.5}
14.5 {54.9}
36.9 {2.5}
25 {95}
2
0.5 {0.4}
5300
{150,075}
1.5 {1.1}
2 {1.5}
21.0 {79.5}
31.6 {2.2}
25 {95}
2
0.5 {0.4}
5300
{150,075}
2 {1.5}
2 {1.5}
26.3 {99.6}
36.1 {2.5}
25 {95}
4
0.5 {0.4}
9800
{277,505}
49 {1245}
34 {864}
39.5 {1003}
49 {1245}
34 {864}
45.5 {1156}
610 {277}
750 {340}
830 {376}
1000 {454}
run
11.0
14.7
5.3
7.7
4.2
run
full
13.3 20.8
17.1 24.8
6.5
9.4
9.0 12.4
5.2
7.5
full
19.6
23.6
8.9
11.8
7.1
53.5 {1359}
34 {864}
55 {1397}
830 {376}
1000 {454}
run
18.6
21.5
9.0
11.4
7.2
1
full
32.2
35.5
14.6
17.8
11.7
1030 {467}
1200 {544}
run
23.7
27.7
11.6
14.8
9.3
full
33.3
37.6
15.1
18.8
12.1
71 {1524}
34 {864}
55 {1397}
1030 {467}
1200 {544}
run
27.8
29.9
13.5
16.0
10.8
full
40.1
42.6
18.2
21.3
14.5
1230 {558}
1400 {635}
run
38.6
41.2
18.9
22.2
15.1
full
47.2
50.0
21.4
25.0
17.1
1230 {558}
1600 {726}
run
47.2
50.2
23.2
27.2
18.6
1.5
full
62.7
66.1
28.4
33.0
22.7
75 {1905}
34 {864}
55 {1397}
1440 {653}
1800 {816}
run
57.4
60.0
28.3
32.6
22.6
full
76.9
79.9
34.8
40.0
27.8
SPECIFICATION NOTES
✝ Based on 50 °F (10 °C) water temperature (100% water) leaving the chiller, standard pump selections, 95 °F (35 °C) ambient air conditions for
the 60 Hz units. For the 50 Hz units, multiply the capacity by 0.8. Consult factory for other conditions. Capacity ratings are (+-) 5% based on
compressor manufacturer’s ratings and are subject to change without notice.
‡ Based on 50 °F (10 °C) water temperature leaving the chiller and 60 °F (16 °C) water temperature returning to the chiller (except A1-1.5 and
A1-2.25 which have 55 °F (13 °C) water temperature returning to the chiller).
§ Pressure at pump discharge. See Pressure Tables in the Appendix for evaporator and condenser pressure drops.
* Optional
UGH017/0500
Series 1 Portable Chillers, PLC Control
DESCRIPTION
2-11
PUMP CURVES
Pressure (psi)
60 HZ PUMP PERFORMANCE CURVES
Flow Rate (gpm)
Pressure (psi)
50 HZ PUMP PERFORMANCE CURVES
Flow Rate (gpm)
2-12
DESCRIPTION
Series 1 Portable Chillers, PLC Control
UGH017/0500
INSTALLATION
● Unpacking the Boxes . . . . . . . . . .3-2
● Warnings and Cautions . . . . . . . . .3-3
● Preparing for Installation . . . . . . .3-4
● Making Process Plumbing
Connections . . . . . . . . . . . . . . . .3-5
● Filling the Chiller . . . . . . . . . . . . . .3-6
● Checking Refrigerant Charge . . . .3-8
● Connecting the Main
Power Source . . . . . . . . . . . . . . .3-9
● Checking Electrical Connections 3-10
● Initially Starting the Chiller . . . . .3-10
● Connecting the Remote Control .3-11
● Checking for Leaks . . . . . . . . . . .3-12
● Stopping the Chiller . . . . . . . . . .3-13
Series 1 Portable Chillers, PLC Control
UGH017/0500
3-1
UNPACKING THE
BOXES
The portable chiller comes fully assembled in a single crate.
CAUTION: Lifting
The Series 1 Portable Chillers are designed to
easily roll on casters. If, for some reason you
need to lift the chiller, take all precautions to
avoid personal injury or damage to the chiller.
Lift the chiller using a forklift or hoist with straps
that have been positioned about the chillers’
center of gravity. Do not try to lift the unit manually.
1
Carefully uncrate the chiller
and its components.
2
Remove all packing material, protective paper,
tape, and plastic. Compare contents to the shipping papers
to ensure that you have all the parts.
3
Carefully inspect all components to make sure
no damage occurred during shipping. If any damage is
found, notify the shipping agent immediately. Check all
wire terminal connections, bolts, and any other electrical
connections, which may have come loose during shipping. Check for pinched wires and kinked hoses.
4
Record serial numbers and specifications
in the blanks provided on the back of the User Guide’s
title page. This information will be helpful if you ever
need service or parts.
3-2
INSTALLATION
Series 1 Portable Chillers, PLC Control
UGH017/0500
WARNING: Improper installation, operation, or servicing may result in equipment damage or personal injury.
This equipment should only be installed, adjusted, and serviced by qualified technical personnel who are familiar with the construction, operation, and potential hazards of this type of
machine.
WARNINGS
CAUTIONS
AND
All wiring, disconnects and fuses should be
installed by qualified electrical technicians in
accordance with electrical codes in your region.
Always maintain a safe ground. Do not operate
the equipment at power levels other than what
is specified on the machine serial tag and data
plate.
CAUTION: Hot Surfaces
Always protect yourself from hot surfaces when
working on the Portable Chiller, especially when
working on or around the compressor and condenser. These devices can reach up to 160 °F
(71 °C). Allow these devices to cool before performing any maintenance or troubleshooting.
CAUTION: Ventilation
The unit requires a clean and well ventilated
operating environment. Do not place anything
on top of the unit while operating. Units with
fans require unrestricted outlet air flow.
Water-cooled units require a minimum of one
foot clearance around the perimeter for serviceability. Air-cooled units require a minimum of two
feet clearance around the perimeter for serviceability and proper air flow.
WARNING: Refrigerant hazard
Only certified refrigerant technicians should
examine and correct problems involving the
refrigerant circuit.
UGH017/0500
Series 1 Portable Chillers, PLC Control
INSTALLATION
3-3
PREPARING FOR
INSTALLATION
Plan the location for the chiller and prepare the area properly.
Position the Chiller as close to the process machine as possible. Place the chiller in position near the process machine so
that fluid lines can be connected from the process machine to
the chiller and back.
Chiller
Process machine
Alternate
locations
Make sure the area where the chiller is installed has:
● A grounded power source.
Check the chiller’s serial tag for the correct amps, voltage, phase, and cycle. All wiring should be completed by
qualified personnel and comply with your region’s electrical codes.
● Clearance for safe operation and maintenance.
Make sure there is two feet clearance around the chiller
for proper operation, maintenance, and servicing. After
positioning, lock casters to prevent chiller from moving.
24 inches
(610 mm)
24 inches
(610 mm)
24 inches
(610 mm)
24 inches
(610 mm)
● Available water source.
If installing a water-cooled unit, make sure condenser
water source is plumbed to chiller installation location.
High points in plumbing require vent valves; low points
require drain valves.
3-4
INSTALLATION
Series 1 Portable Chillers, PLC Control
UGH017/0500
Warm fluid from process equipment enters the chiller at the
From Process connection and chilled fluid returns to the
process equipment through the To Process connection.
1
Remove the shipping plastic pipe plug from
the female connections on the back of the portable chiller.
2
Make sure the male pipe threads are clean
MAKING
PROCESS
PLUMBING
CONNECTIONS
and new.
3
Wrap threads with Mylar or Teflon tape.
4
Connect the From Process connection on the
5
Connect the To Process connection on the
back of the chiller to the From Process hose. Start by
hand until the threads engage and then tighten with a pipe
wrench. Tighten only enough to prevent leaks; do not
over-tighten!
back of the chiller to the return hose. Start by hand until
the threads engage and then tighten with a pipe wrench.
Tighten only enough to prevent leaks; do not over-tighten!
If you unit does not have
the optional To Process
valve and From Process
valve, you may want to
install valves on the To
Process and From
Process connections to
more easily control
process fluid into and
out of the chiller.
For Water-cooled Chillers connect the cooling water source to
the Condenser Water inlet on the back of the chiller. Connect
the Condenser Water outlet to the cooling water source’s
return.
back view
Condenser
Water outlet
(water-cooled only)
Condenser
Water onlet
(water-cooled only)
From Process
connection
To Process
connection
UGH017/0500
Series 1 Portable Chillers, PLC Control
INSTALLATION
3-5
The Chiller is shipped without coolant. The chiller is filled
manually during installation. Use water as the coolant down to
40 °F (4 °C). Below 40 °F and down to 20 °F (-7 °C), use an
ethylene glycol or propylene glycol solution.
FILLING THE
CHILLER
To fill with water:
1
2
3
Attach water hose to Fill/Drain valve.
Close the To Process and From Process valves.
Open the Fill/Drain valve and fill chiller
to the fill mark on the Water Level gauge. If the chiller is
overfilled, the excess water spills out the vent tube.
DO NOT OVERFILL.
4
5
Close the Fill/Drain valve.
Disconnect water hose from Fill/Drain valve.
From Process
connection
Water level
gauge
To Process
connection
Fill/Drain valve
To fill with glycol solution:
1
Mix the glycol to the proper percentage.
Use the table to determine the percentage (by volume) of
glycol needed for the process temperature (in °F) you
require. Do not choose a temperature below 15 °F (-9 °C).
Mix the proper percentage of glycol with water.
3-6
INSTALLATION
Series 1 Portable Chillers, PLC Control
UGH017/0500
Glycol, % by Volume
FILLING THE
CHILLER
CONT’D
Temperature of Process Fluid °F
2
3
Close the To Process and From Process valves.
Open the Fill/Drain valve and fill chiller
to the fill mark on the Water Level gauge. If the chiller is
overfilled, the excess fluid spills out the vent tube. DO
NOT OVERFILL.
4
5
Close the Fill/Drain valve.
Check the coolant level.
Once the chiller is turned on, the coolant level may drop
as the coolant begins to circulate, filling the connected
plumbing. Check the coolant level on the back of the
chiller. The coolant level shows on the water level gauge.
Make sure coolant level is filled to the mark on the gauge.
6
Set the Chiller control for ‘Percent Glycol’.
Set the percent glycol using the PLC control (see Setting
Percent Glycol, in the Operation section). Do this step
after main power is connected to the chiller and initial
startup has already been performed.
UGH017/0500
Series 1 Portable Chillers, PLC Control
INSTALLATION
3-7
CHECKING
REFRIGERANT
CHARGE
All chillers are fully charged with refrigerant at the factory.
Your chiller’s model nameplate identifies the type and amount
of total refrigerant charge required.
Check refrigerant charge while the chiller is running. Check
the refrigerant charge through the site glass. For water-cooled
models open the side panel; for air-cooled models, locate the
site glass through the wire mesh side panel. Use a flashlight, if
necessary, and check the site glass:
● Under full load conditions, the refrigerant should be
clear (no bubbles).
● Under low load conditions, when the hot-gas bypass
valves are operating, bubbles may be visible in the
sight glass. This is normal.
If the charge is low contact Conair service or have a local, certified refrigeration technician add refrigerant to the system.
WARNING: Refrigerant hazard
Only certified refrigerant technicians should
examine and correct problems involving the
refrigerant circuit.
If your Chiller is still under warranty you must
Contact Conair Service before contacting a contractor to service your Chiller.
Sight
glass
3-8
INSTALLATION
Series 1 Portable Chillers, PLC Control
UGH017/0500
WARNING: Improper installation, operation, or servicing may result in equipment damage or personal injury.
This equipment should only be installed, adjusted, and serviced by qualified technical personnel who are familiar with the construction, operation, and potential hazards of this type of
machine.
CONNECTING
THE MAIN
POWER SOURCE
All wiring, disconnects and fuses should be
installed by qualified electrical technicians in
accordance with electrical codes in your region.
Always maintain a safe ground. Do not operate
the equipment at power levels other than what
is specified on the machine serial tag and data
plate.
WARNING: Electrical hazard
Before performing any work on this item, disconnect and lock out electrical power sources to
prevent injury from unexpected energization or
startup.
1
2
Open the chiller’s electrical enclosure.
Connect the power wires
to the terminals (see the wiring
diagrams that came with your
machine). Route the power
cable through the hole in the
side of the chiller to the electrical enclosure.
3
Check terminal screws
to make sure wires are secure.
Gently tug each wire; if wire is loose, use a
screwdriver to tighten the terminal.
4
The 575V, 1 1/2 - 4 Hp
units utilize a transformer;
power wires must be connected to the line side of
the transformer.
Grounding
lug
Connect the ground wire to grounding lug.
UGH017/0500
Series 1 Portable Chillers, PLC Control
INSTALLATION
3-9
CHECKING
ELECTRICAL
CONNECTIONS
WARNING: Electrical hazard
Before performing any work on this item, disconnect and lock out electrical power sources to
prevent injury from unexpected energization or
startup.
1
2
Open electrical enclosure.
Check the short-to-ground with an ohm meter.
Connect the ohm meter to each of the three terminal
screws and to the grounding lug. Test all three for resistance. The maximum resistance to ground should be 1
megohm. If it resistance is more than 1 megohm there is a
leak in the system.
If you disconnect the Chiller
from the main power supply
and reconnect it, the Chiller
needs 15 minutes for the
crankcase heater to warm
up. You can not use the
Chiller during this time.
Test each for
resistance
Grounding
lug
3
Close the electrical enclosure.
The Chiller is now ready for initial startup.
INITIALLY
STARTING THE
CHILLER
1
Turn on main power source.
The control boots up and the screen displays the Portable
Chiller model number.
Conair Chiller
A1 - 5
WARNING: Initial startup
Do not press any buttons after initially applying
power to the Chiller. Let the Chiller set, undisturbed, for a minimum of 8 hours before starting
the Chiller. This is necessary to allow the
crankcase heater to warm properly, and to prevent the refrigerant from pooling in the compressor.
3-10
INSTALLATION
Series 1 Portable Chillers, PLC Control
UGH017/0500
After the initial 8-hour minimum warmup, continue with startup:
2
Press the Next arrow on the control to move
to the Main screen.
CONT’D
The Main screen displays:
STATUS
3
INITIALLY
STARTING THE
CHILLER
SETUP RUN ALM
Press the Run arrow.
STATUS
SETUP RUN ALM
press arrow
The Run screen displays:
RUN
PUMPDOWN
press arrow
4
Press the RUN arrow.
Verify that the Chiller begins to run. Check that the
Compress light and the Process Pump light on the control
panel are lit.
5
Check the rotation of the pump.
If pump is not turning, disconnect main power to chiller,
swap any two wires; reapply main power. Check for
leaks.
6
If you get an alarm message on the display:
If you get a Compressor Backwards, Shut Off, Swap
Leads message, press the Stop Chiller button, unplug
Chiller from main power supply, switch any two compressor leads, and apply main power supply. Wait three minutes and then press Run arrow.
7
When the compressor is shut
off it cannot be turned on
again for three minutes. This
allows temperatures and
pressure in the chiller to
equalize, making restart easier, and prolonging the life of
the chiller.
Press the Escape/Previous button to
return to the Main screen.
UGH017/0500
Series 1 Portable Chillers, PLC Control
INSTALLATION
3-11
CHECKING
LEAKS
FOR
Before placing the Chiller into operation you need to check
for fluid leaks. Do this by turning on the pump from the control and letting it run while you check inside the chiller.
From the main screen:
1
Press the Run arrow on the screen.
STATUS
SETUP RUN ALM
press arrow
2
Press the Scroll arrows to scroll
to the Manual Pump screen.
The Manual Pump screen displays:
Manual Pump
3
ON OFF
Press the Pump ON arrow.
Check inside the chiller for any leaks.
If you find leaks:
1
Press the Stop Chiller button on the
control panel.
2
3
Press the Manual Pump OFF arrow.
Disconnect the Chiller from the
main power supply.
4
Repair any leaks.
Dry any moisture inside the Chiller.
5
3-12
INSTALLATION
Reconnect the main power supply.
Series 1 Portable Chillers, PLC Control
UGH017/0500
If your chiller has the optional remote interface, you need to
connect it to the chiller control. The chiller control panel is
hinged on the bottom. Pull down on the top of the outer bezel
of the control to expose the internal wiring. Plug the interface
cable from the remote controller into the communication cable
connection.
CONNECTING
THE
REMOTE
CONTROL
Communication
connection
To stop the chiller, press the Stop Chiller button on the control
panel.
STOPPING THE
CHILLER
The compressor shuts off after a few seconds and the pump
shuts off a few seconds later. This allows the chiller to pump
down the refrigerant system and store the refrigerant in the
receiver. This prolongs the life of the chiller.
NOTE: If you want to restart the chiller immediately after
stopping it, pressing the Run arrow on the display starts the
pump (the Process Pump light on the control panel lights) but
the compressor will not turn on for three minutes. After three
minutes the compressor turns on and the Compressor light on
the control panel lights. This allows temperatures and pressure
to equalize, making restart easier, and prolonging the life of
the chiller.
If the chiller is not working properly at any time, stop the
chiller and refer to the Troubleshooting section. If you do not
encounter any problems, proceed to the Operation section.
UGH017/0500
Series 1 Portable Chillers, PLC Control
INSTALLATION
3-13
OPERATION
● PLC Control Features . . . . . . . .4-2
● Before Starting . . . . . . . . . . . . . .4-3
● Powering Up . . . . . . . . . . . . . . . .4-4
● Running/Stopping the Chiller . .4-5
● Viewing Chiller Status . . . . . . . .4-6
● Programming Settings . . . . . . . .4-8
● Changing Setpoint
Temperature . . . . . . . . . . . . . .4-9
● Resetting PID Settings . . . . . . .4-10
● Changing High Temperature
Deviation . . . . . . . . . . . . . . . .4-11
● Setting Percent Glycol . . . . . . .4-12
● Setting Fan Setpoints . . . . . . .4-14
● Setting Auto Tune Mode . . . . . .4-16
● Manually Starting/
Stopping the Pump . . . . . . . .4-18
Series 1 Portable Chillers, PLC Control
UGH017/0500
4-1
PLC CONTROL
FEATURES
Display screen
shows status, setup
and run modes
Status lights
show the run status of compressor, process pump, and
alarm/shutdown
4-2
Option arrows
Up / Down Scroll arrows
choose parameters displayed on the screen
scroll through the display
screens
Drop-open bezel
PLC Indicator lights
Navigation buttons
allows access for
maintenance
show power, program
and service indications
save new settings and
return to main screen
OPERATION
Stop Chiller button
Numerical keypad
press to stop chiller
choose and change
numerical values
Series 1 Portable Chillers, PLC Control
UGH017/0500
Before you start daily operation of the chiller, you need to
perform scheduled preventative maintenance. Necessary maintenance is describe in the Maintenance section of this Users
Guide.
BEFORE
STARTING
WARNING: Electrical hazard
Be sure that power to the chiller is OFF when
doing any maintenance on the chiller. Follow all
safety rules when performing any maintenance
on this equipment.
Daily maintenance includes:
● Checking electrical connections
● Checking process fluid level in the pump tank
● Checking the condenser coil for debris (air-cooled
only)
● Verifying pump discharge pressure
● Inspecting piping for leaks.
NOTE: The daily, weekly, monthly, and semi-annual maintenance procedures are detailed in the Maintenance section. Go
there for the detailed maintenance descriptions.
Before starting the Chiller be sure to:
● Open the To Process connection
to the full open position.
● Open the From Process connection
to the 3/4 open position. You will need to adjust this
valve when the chiller is running to obtain the desired
pump discharge pressure. To find the approximate
water flow, refer to the pump curves in Description
section.
From Process
connection
To Process
connection
UGH017/0500
Series 1 Portable Chillers, PLC Control
OPERATION
4-3
POWERING UP
Plug in the power cord to restore power after any required
maintenance. The Chiller requires 15 minutes warmup time
after it is plugged in for the crankcase heater to warm up.
1
Turn on the main power.
The chiller control automatically performs its bootup routine. the screen displays the Portable Chiller model number along with the Enter command.
Conair Chiller
A1 - 5
2
Press the Scroll arrow to move
to the Main screen.
The main screen displays:
STATUS
SETUP RUN ALM
The main screen lets you:
If you disconnect the Chiller
from the main power supply
and reconnect it, the Chiller
needs 15 minutes for the
crankcase heater to warm
up. You can not use the
Chiller during this time.
● view the status of the water level, process temperature,
suction pressure, percent glycol, low temperature
cutout and discharge pressure.
● view and change the setups for temperature setpoint,
Auto tune mode, high temperature deviation, and percent glycol solution
● run or stop the chiller
● view alarm information
● perform maintenance with password clearance
3
Press the arrow pointing to the selection
you want displayed on the screen.
STATUS
SETUP RUN ALM
Choose a selection
4-4
OPERATION
Series 1 Portable Chillers, PLC Control
UGH017/0500
After you have viewed all the Status screens and made any
necessary changes to the Setup screens, you are ready to run
the Chiller. To run the Chiller from the main screen:
1
Press the Run arrow on the Main screen.
STATUS
RUNNING/
STOPPING
THE CHILLER
SETUP RUN ALM
press arrow
2
Press the arrow pointing to your choice.
If the Chiller is stopped and you want to run it, press the
arrow pointing to RUN.
RUN
PUMPDOWN
Select one
If you disconnect the Chiller
from the main power supply
and reconnect it, the Chiller
needs 15 minutes for the
crankcase heater to warm
up. You can not use the
Chiller during this time.
If you want to stop the chiller and continue to run the
pump, choose PUMPDOWN.
3
Press the Escape/Previous Screen button.
The control returns to the main screen.
To stop the chiller at any time, press the red Stop Chiller button on the control panel.
The chiller control and display screen remain on, but the
pump and compressor stop.
If you want to restart immediately, the pump will turn on but
the compressor will not turn on for three minutes. The
Process Pump light on the control panel will light immediately. After three minutes the compressor turns on and the
Compressor light on the control panel lights.
UGH017/0500
Series 1 Portable Chillers, PLC Control
OPERATION
4-5
VIEWING
CHILLER
STATUS
The Status screens are read-only screens. You cannot make
changes to these screens. To view the status screens:
1
Press the Status arrow on the Main screen.
STATUS
SETUP RUN ALM
Press arrow
2
Use the scroll arrows to scroll through the
status screens.
The Status button does not
let you change the status,
only view it.
● Temperatures - displays the To Process temperature
and the Setpoint temperature. Check that the temperatures
are the proper settings. To change the Setpoint temperature, go to Changing the Setpoint Temperature, in the
Operation section.
Temperature
Set Point
45 F
40 F
● Percent chiller load - shows the current percent of
chiller capacity being used. This percentage cannot be
changed manually. It is a read-only value. This value
changes as the chiller cycles.
Chiller % Loading
70 %
● Water level - displays the current status of the water
level. Screen displays Level Okay, or Level Low. If the
level is low, see Filling the Chiller, in the Installation section.
Water Level
Level Okay
4-6
OPERATION
Series 1 Portable Chillers, PLC Control
UGH017/0500
● Refrigerant suction pressure - shows the status of the
refrigerant suction pressure in PSIG. NOTE: Typical
refrigerant suction pressure is between 55 PSIG and 95
PSIG.
Ref Suction Pressure
70 PSIG
VIEWING
CHILLER
STATUS
CONT’D
● Refrigerant Discharge pressure - View the status of
the refrigerant discharge pressure in PSIG. Typical discharge pressure is between 190 PSIG and 325 PSIG.
Ref Discharge Pressure
250 PSIG
● Percent Ethylene Glycol by Volume and Low temperature Cutout - displays the percentage of ethylene
glycol or propylene glycol solution (by volume) in the
chiller in degrees Fahrenheit. Changing the percent glycol
automatically changes the low temperature cutout.
% E.G. BY VOL
LOW TEMP CUTOUT
0
40 F
Verify that the readings each screen displays are the ones
you want. You cannot change the readings of the screens
from the Status screens. You can change to status of:
● Setpoint temperature
● Percent Ethylene Glycol by volume
by going to the Setup screens. You can not change the
other readings; they are read-only screens, reporting environmental conditions.
3
Press the Escape/Previous button at any time
to return to the main screen.
UGH017/0500
Series 1 Portable Chillers, PLC Control
OPERATION
4-7
PROGRAMMING
SETTINGS
The PLC control allows you to program various parameters
for the Chiller:
● Temperature Setpoint
The desired To Process fluid temperature.
● Auto Tune PID
Helps maintain the setpoint temperature without overshooting.
● High Temperature Deviation
Set the number of degrees the temperature can rise
above the setpoint temperature without an alarm.
● Percent Glycol by Volume
Use when you use an ethylene glycol or propylene glycol solution to lower the To Process temperature.
Changing the percent glycol automatically changes and
displays the low temperature cutout, in °F.
● Fans (Air-cooled only)
Set the upper and lower pressure setpoints (in PSI) for
the fans to cycle. This screen is password protected.
● Maintenance
View times for compressor cycle, pump run time,
pump cycle and hot gas bypass cycle. These screens
are password protected.
If you do not need to change
any settings on the control,
go to Running the Chiller.
To program settings from the Main screen:
1
Press the Setup arrow.
STATUS
SETUP RUN ALM
press arrow
The first Setup screen displays:
Temperature
Setpoint
2
45 F
45 F
Press the Up and Down Scroll arrows to
scroll through the Setup screens. Stop at the one you want
to change.
4-8
OPERATION
Series 1 Portable Chillers, PLC Control
UGH017/0500
Use the Temperature Setpoint screen to set the desired temperature of the To Process fluid.
To display the Setpoint temperature from the Main screen,
press the Setup arrow. The Setpoint screen displays:
CHANGING
SETPOINT
TEMPERATURE
Setpoint
50 F
10 C
number
flashes
The current setpoint temperature displays in both Fahrenheit
(F) and Celsius (C). The temperature in F flashes.
1
Press the arrows to change the setpoint
temperature. Pressing the (-) arrow lowers the temperature
by one degree; pressing the (+) arrow increases the temperature by one degree. Pressing the arrows automatically
changes both scales.
Setpoint
50 F
10 C
Press arrows
OR
Use the numeric keypad
to adjust the setpoint temperature. Press the appropriate
numbers for the desired temperature, then press the Enter
button to save.
2
Press the scroll arrows to move to the next
setup screen, or press Escape/ Previous Screen button to
return to the main screen.
UGH017/0500
Series 1 Portable Chillers, PLC Control
OPERATION
4-9
RESETTING PID
SETTINGS
Use the PID reset to return the control to the factory settings.
To reset PID from the main screen:
1
Press the Setup arrow.
STATUS
SETUP RUN ALM
Press arrow
2
Press the Scroll arrows to scroll through the
Setup screens. Stop when you get to the PID Reset
screen.
3
Press the PID Reset arrow.
PID Reset
FANS
Press arrow
4
Press the scroll arrows to move to the next
setup screen, or press Escape/ Previous Screen button to
return to the main screen.
4-10
OPERATION
Series 1 Portable Chillers, PLC Control
UGH017/0500
Decide how many degrees above the setpoint temperature you
want the chiller to deviate before an alarm occurs.
To set the high temperature deviation:
1
Press the Setup arrow.
STATUS
CHANGING HIGH
TEMPERATURE
DEVIATION
SETUP RUN ALM
press arrow
Continue to press the arrow to scroll through the Setup
screens. Stop when you get to the Deviate High screen.
The current high temperature deviation number displays
along with the - and +. The number flashes on the screen.
High Temp Dev
20
number flashes
2
Press the - or + arrows to set the high
deviation to the appropriate number. Each press of the (-)
arrow decreases the high deviation by one unit; each press
of the (+) arrow increases the high deviation by one unit.
Stop when you reach the desired temperature deviation.
The allowable range is 3 to 20 units.
High Temp Dev
18
Press arrows
3
Press the Scroll arrows to scroll to the
the next Setup screen, or press the Escape/Previous
Screen button to return to the main screen.
UGH017/0500
Series 1 Portable Chillers, PLC Control
OPERATION
4-11
SETTING
PERCENT
GLYCOL
To set the percent ethylene glycol or propylene glycol solution
determine the desired temperature of the process fluid leaving
the chiller.
Use water as the coolant for a setpoint temperature of the
process fluid down to 40 °F (4 °C). Below 40 °F and down to
20 °F (-7 °C), a glycol solution is required.
Use the table to choose the proper percentage of glycol solution for the required temperature.
Glycol, % by Volume
NOTE: If you are using
water as the coolant, set
the Percent Glycol to
zero on the control.
This screen is password
protected. You must
have clearance to enter
and change this setting.
Temperature of Process Fluid °F
After choosing the desired setpoint temperature, mix the glycol solution to the proper percentage and fill the chiller
according to the directions in Filling with Glycol Coolant, in
the Installation section.
Program the percentage glycol solution into the control. From
the main screen:
1
Press the Setup arrow.
STATUS
SETUP RUN ALM
press arrow
4-12
OPERATION
Series 1 Portable Chillers, PLC Control
UGH017/0500
2
Press the Up/Down Scroll arrows to scroll
through the setup screens.
SETTING
PERCENT
GLYCOL
CONT’D
Stop when you get to the Percent Glycol screen:
% E.G. BY VOL
Low Temp Cutout
0%
36F
number
flashes
The screen displays the percent of glycol by volume currently used. This number is flashing. The screen also displays the low temperature cutout (If the To Process fluid
drops below this temperature, an alarm condition occurs
and the compressor shuts off.)
3
NOTE: If you are using
water as the coolant, set
the Percent Glycol to
zero on the control.
Use the numeric keypad to set the percent
glycol. Make sure the percent you enter is the same as the
percent mixture you added to the chiller. See Filling with
Glycol Coolant, in the Installation section.
NOTE: This screen has password protection. You can
change the percent glycol only if you have clearance. A
screen displays: $316 Password level invalid...
The password screen then displays, asking for the password. Enter the password, then press the Enter button.
You now have password access for five minutes.
Otherwise, press the Escape button to return to the Main
screen.
4
Press the Scroll arrows to scroll to the
next Setup screen, or press the Escape/Previous Screen
button to return to the main screen.
UGH017/0500
Series 1 Portable Chillers, PLC Control
OPERATION
4-13
SETTING FAN
SETPOINTS
For the Air-cooled Chillers you can choose the pressure, in
pounds per square inch, at which the fans cycle. To set the Fan
Setpoints from the main screen:
1
Press the Setup arrow.
STATUS
SETUP RUN ALM
Press arrow
2
Press the Scroll arrows to scroll through the
Setup screens. Stop when you get to the PID Reset
screen.
This screen is password
protected. You must
have clearance to enter
and change this setting.
3
Press the Fans arrow.
PID Reset
FANS
Press arrow
A screen displays asking for the password. Use the
Keypad to enter the password and then press the Enter
button. The Fan Setpoint screen displays:
Fan 1
limits
ON
OFF
250
190
number
flashes
The screen shows the upper and lower pressure limits for
Fan 1 (the pressure, in PSI, when the fans turn on and
off). The ON pressure flashes. Use the keypad to change
this number. Then press the Enter button to save the new
number. Set from 190 PSI to 300 PSI.
4
Press the Scroll arrow to move to
the OFF setting. The OFF number flashes:
Fan 1
limits
ON
OFF
245
190
number
flashes
Use the keypad to change the OFF number.
4-14
OPERATION
Series 1 Portable Chillers, PLC Control
UGH017/0500
5
Press Enter to save the change.
SETTING FAN
SETPOINTS
CONT’D
6
Press the scroll arrows to move to Fan 2.
Repeat the steps for changing Fan 2 setpoint temperatures.
7
Press the Escape/Previous Screen button
to return to the main screen.
UGH017/0500
Series 1 Portable Chillers, PLC Control
OPERATION
4-15
SETTING AUTO
TUNE MODE
Use the Auto Tune Mode to maintain good temperature control and minimize overshooting the setpoint temperature.
To display the Auto Tune Mode from the main screen:
1
Press the Setup arrow.
STATUS
SETUP RUN ALM
Press arrow
This screen is password protected. You must have clearance to enter and change
settings on this screen.
2
Press the Scroll arrows to scroll
to the Maintenance screen.
3
Press the Maintenance arrow.
Maintenance
Press arrow
The password screen displays.
4-16
OPERATION
4
Use the keypad to enter the password.
5
Press the Enter button.
Series 1 Portable Chillers, PLC Control
UGH017/0500
6
SETTING AUTO
TUNE MODE
Press the Scroll arrows to scroll
to the Tune screen.
CONT’D
TUNE
Press arrow
7
Press the Auto Tune arrow.
The control begins tuning. This takes about 15 seconds.
When tuning, the screen displays ‘TUNE Tuning’ message. When tuning is complete, the screen displays
‘TUNE Normal’ message.
8
Press the Escape/Previous Screen button
to exit the Maintenance screens and return to the main
screen.
UGH017/0500
Series 1 Portable Chillers, PLC Control
OPERATION
4-17
MANUALLY
STARTING/
STOPPING THE
PUMP
To run or stop the pump from the main screen:
1
Press the arrow pointing to Run on the screen.
STATUS
SETUP RUN ALM
press arrow
The first Run screen displays.
2
Use the Scroll arrows to scroll through
Run screens to the Manual Pump screen.
3
Press the arrow pointing to your choice.
If the pump is running and you want to stop it, press the
arrow pointing to Off. If the pump is stopped and you
want to run it, press the arrow pointing to On.
Manual Pump
ON OFF
Select one
4
Press the Escape/Previous Screen button.
The control returns to the main screen.
4-18
OPERATION
Series 1 Portable Chillers, PLC Control
UGH017/0500
MAINTENANCE
● Maintenance Features . . . . . . . .5-2
● Warnings and Cautions . . . . . . .5-3
● Preventative Maintenance
Schedule . . . . . . . . . . . . . . . . .5-4
● Entering Maintenance Screens .5-6
● Checking Electrical
Connections . . . . . . . . . . . . . .5-8
● Cleaning the Evaporator or
Water-cooled Condenser . . . .5-9
● Cleaning the Air-cooled
Condenser . . . . . . . . . . . . . . .5-10
● Checking the Refrigerant
Charge . . . . . . . . . . . . . . . . . .5-11
● Checking Reservoir Level . . . .5-12
Series 1 Portable Chillers, PLC Control
UGH017/0500
5-1
MAINTENANCE
FEATURES
Conair Series 1 Portable Chillers need regular, scheduled
maintenance for peak performance.
To maintain the best performance of the chiller, it must be
cleaned and inspected regularly. Maintenance includes a daily,
monthly, and semi-annual schedule.
Use this maintenance schedule as a guide. You may need to
shorten the time of the maintenance schedule, depending on
how often you use the chiller. Among the features that require
preventative maintenance are:
●
●
●
●
●
●
●
●
●
5-2
MAINTENANCE
the refrigerant system
electrical cables, terminals, and control lights
the condenser
caster locks
temperature and pressure readings
process fluid level
chiller efficiency
evaporator
cooling water treatment system (water-cooled models)
if a cooling tower is used to cool the condensers
Series 1 Portable Chillers, PLC Control
UGH017/0500
Follow all cautions and warnings when working on the equipment.
WARNING: Improper installation, operation, or servicing may result in equipment damage or personal injury.
WARNINGS
CAUTIONS
AND
This equipment should only be installed, adjusted, and serviced by qualified technical personnel who are familiar with the construction, operation, and potential hazards of this type of
machine.
All wiring, disconnects, and fuses should be
installed by qualified electrical technicians in
accordance with electrical codes in your region.
WARNING: Electrical hazard
Before performing any work on this item, disconnect and lock out electrical power sources to
prevent injury from unexpected energization or
startup. Be sure that power to the chiller is OFF
when performing any maintenance on the
chiller. Follow all safety rules when performing
any maintenance on this equipment.
CAUTION: Hot Surfaces
Always protect yourself from hot surfaces when
working on the Portable Chiller, especially when
working on or around the compressor and condenser. These devices can reach up to 160 °F
(71 °C). Allow these devices to cool before performing any maintenance or troubleshooting.
WARNING: Refrigerant hazard
Only certified refrigerant technicians should
examine and correct problems involving the
refrigerant circuit.
UGH017/0500
Series 1 Portable Chillers, PLC Control
MAINTENANCE
5-3
PREVENTATIVE
MAINTENANCE
SCHEDULE
● Daily, or as often as needed
❒ Checking electrical connections
Make sure electrical connections are properly seated.
See Checking Electrical Connections, in the
Maintenance section.
❒ Checking process fluid level in the pump tank
Check the process fluid level in the water level gauge
on the back of the chiller. If low, see Filling the
Chiller, in the Installation section.
To maintain the best performance, follow the maintenance schedule and record
information in the
Maintenance Log in the
Appendix.
❒ Verifying pump discharge pressure
While the pump is running, check that the pump pressure gauges read the correct dischrge pressure. To
change the pressure adjust the From Process valve.
❒ Inspecting piping for leaks
Check to see that pipes are not leaking. Look for
standing water on the floor or inside the chiller cabinet.
❒ Inspecting the condenser coil for debris
(air-cooled models only) Remove the wire mesh side
panel in front of the condenser coil. See Cleaning the
Air-cooled Condensers, in the Maintenance section
● Weekly, or as often as needed
❒ Checking temperature and pressure readings
Check the temperature and pressure display on the
control screen, and the pump pressure gauge to ensure
they indicate normal operation.
❒ Checking efficiency
Review the performance data on the Maintenance Log
found in the Appendix. If you notice a decrease in efficiency over time, check all heat transfer surfaces of the
evaporator and condenser for fouling. Clean as needed.
❒ Checking refrigerant sight glass
There should not be any bubbles unless the hot gas
bypass is cycling. See Checking Refrigerant Charge, in
the Maintenance section.
❒ Checking reservoir level
Check the water level gauge on the back of the chiller.
If fluid level is low, fill. See Checking Reservoir Level,
in the Maintenance section.
5-4
MAINTENANCE
Series 1 Portable Chillers, PLC Control
UGH017/0500
● Monthly
❒ Inspecting cooling water treatment system
If your chiller uses a cooling water treatment system,
maintain proper chemical levels and follow the recommendations of your water treatment specialist. Change
water in the reservoir tank monthly.
❒ Cleaning
Wipe all external surfaces of the Chiller.
❒ Inspecting condenser
Check the condenser for adequate air flow or water
flow. Check the condenser face for dirt and clogging.
If dirt or clogs are present, clean the condenser. See
Cleaning the Evaporator or Water-cooled Condenser,
and Cleaning the Air-cooled Condenser, in the
Maintenance section. If your unit has an optional filter
at the air inlet of the Air-cooled condenser coil, check,
clean, and replace as needed.
❒ Inspecting the control panel
Check for loose wires, burned contacts, and signs of
overheated wires. Check that all panel lights illuminate. See Checking Electrical Connections, in the
Maintenance section.
PREVENTATIVE
MAINTENANCE
SCHEDULE
CONT’D
To maintain the best performance, follow the maintenance schedule and record
information in the
Maintenance Log in the
Appendix.
❒ Checking refrigerant charge
Check the sight glass between the receiver and evaporator to ensure it is clear with no bubbles. See
Checking Refrigerant Charge, in the Maintenance section.
❒ Cleaning process fluid strainer
Remove cap and clean any debris out of strainer.
Replace cap.
● Semi-annual
❒ Cleaning the evaporator or water-cooled condenser
See Cleaning the Evaporator or Water-cooled
Condenser, in the Maintenance section.
❒ Cleaning the tank and float switch
Drain the reservoir. Disconnect all piping from tank
reservoir. Remove the float switch by loosening the nut
on the float switch. Remove switch and clean. Unbolt
the tank from the chiller base. Take off the tank cover
and clean the reservoir. Reinstall the tank cover; reinstall tank. Reinsert float switch, holding firmly against
reservoir and tighten nut. Fill reservoir and check for
UGH017/0500
Series 1 Portable Chillers, PLC Control
MAINTENANCE
5-5
ENTERING
MAINTENANCE
SCREENS
To enter Maintenance screens requires security clearance.
There are two security levels built into the control let you
limit access to the some setup and maintenance screens. The
two security levels are:
● User
Allows user to view all Status screens, access the Run
screens, and access the Setup screens for: temperature
setpoint, high temperature deviation, and PID reset.
The control arrives from the factory at this level.
● Maintenance
Provides all User-level access as well as Fans screen,
percent glycol screen, and Maintenance screens. These
screens are password protected. You cannot enter these
screens without the password (999). After the control
is idle for 5 minutes, it automatically closes out of the
Maintenance screens, returns to the User level, and displays the Temperatures status screen. To return to the
Maintenance level you must re-enter the password.
The Maintenance screens are
password protected. You must
have clearance to enter these
screens.
Use the Maintenance screens to view cycling information.
1
Press the Setup arrow.
STATUS
SETUP RUN ALM
Press arrow
2
Press the Scroll arrows to scroll through the
Setup screens. Stop when you get to the Maintenance
screen:
Maintenance
3
Press the Maintenance arrow.
The password screen displays. Use the keypad to enter the
password, then press the Enter button.
4
Press the CYL arrow.
The first Cycle screen displays. Use the Scroll arrows to
scroll through the Cycle screens. These screens show the
cycle time in hours:
5-6
MAINTENANCE
Series 1 Portable Chillers, PLC Control
UGH017/0500
Compressor Run Time
in hours
15
ENTERING
MAINTENANCE
SCREENS
CONT’D
Compressor Cycles
34
Pump Run Time in hours
22
Pump Cycles
45
Hot Gas Bypass
Cycles
5
31
Press the Escape/Previous Screen button
to exit the Maintenance screens and return to the main
screen. The password stays in effect for 5 minutes after
using it; after 5 minutes the screens return to the User
level.
UGH017/0500
Series 1 Portable Chillers, PLC Control
MAINTENANCE
5-7
CHECKING
ELECTRICAL
CONNECTIONS
WARNING: Electrical hazard
Before performing any work on this item, disconnect and lock out electrical power sources to
prevent injury from unexpected energization or
startup.
WARNING: Improper installation, operation, or servicing may result in
equipment damage or personal injury.
This equipment should only be installed, adjusted, and serviced by qualified technical personnel who are familiar with the construction, operation, and potential hazards of this type of
machine.
All wiring, disconnects, and fuses should be
installed by qualified electrical technicians in
accordance with electrical codes in your region.
1
Be sure the main power is disconnected
and the chiller is locked out. Always disconnect and lockout the main power source before opening the unit for
servicing.
2
3
Always refer to the
wiring diagrams you
received with your chiller
to locate specific electrical components.
Open the electrical enclosure.
Inspect all wires and connections.
Look for loose wires, burned contacts, and signs of overheated wires. Compare the PLC wiring to the wiring diagrams you received with your chiller. Have a qualified
electrician make any necessary repairs or replacements.
4
5
Close the electrical enclosure door.
Inspect the exterior power cords.
Cords should not be crimped, exposed, or rubbing against
the frame. If the main power cord runs along the floor,
make sure it is positioned where it could not rest in pooling water or could not be run over and cut by wheels or
casters.
5-8
MAINTENANCE
Series 1 Portable Chillers, PLC Control
UGH017/0500
Minerals and other contaminants produce deposits, scales,
slime, or algae on the heat transfer surfaces exposed to water.
Fouled surfaces result in decreased cooling capacity.
Implement a water treatment program to slow the fouling.
CAUTION: Hot Surfaces
Always protect yourself from hot surfaces when
working on the Portable Chiller, especially when
working on or around the compressor and condenser. These devices can reach up to 160 °F
(71 °C). Allow these devices to cool before performing any maintenance or troubleshooting.
CLEANING THE
EVAPORATOR
OR WATERCOOLED
CONDENSER
Water quality should be maintained at a pH of 7.4, but not less
that 6.0 for proper heat exchanger life.
To clean:
1
Prepare a 5% solution of Phosphoric acid
or Oxalic acid. Do not heat the acid solution.
2
3
Shut the From Process valve.
Disconnect the pump from the heat exchanger.
Install a cap in the opening of the heat exchanger where
the pump was connected.
4
Connect 1/2-inch tubing to the 1/2-inch
connections of the heat exchanger.
5
Back-flush the solution through the
heat exchanger and the chiller.
6
Flush the heat exchanger and the chiller
piping with fresh water after cleaning.
7
In
Out
Reconnect the chiller pump to the
Out
heat exchanger. Remove the cap in the heat exchanger
and reconnect the hose from the pump.
In
Heat
Exchanger
1/2 inch connection on
outside of chiller cabinet
Fluid circuit
Acid solution
To Process connection
UGH017/0500
Series 1 Portable Chillers, PLC Control
MAINTENANCE
5-9
CLEANING THE
AIR-COOLED
CONDENSER
WARNING: Electrical hazard
Before performing any work on this item, disconnect and lock out electrical power sources to
prevent injury from unexpected energization or
startup.
CAUTION: Hot Surfaces
Always protect yourself from hot surfaces when
working on the Portable Chiller, especially when
working on or around the compressor and condenser. These devices can reach up to 160 °F
(71 °C). Allow these devices to cool before performing any maintenance or troubleshooting.
The air-cooled condenser can accumulate dirt and clog quickly if it is run in a dusty or dirty environment. A clogged condenser increases refrigerant discharge pressure, lowers performance, and may cause the fan motors and compressor to overheat.
1
Inspect the coils.
Use a flashlight to check between coil surfaces.
2
3
Clean the dirty coils with a soft brush.
Flush with cool water or a commercial
coil cleaner.
If your unit has the optional air filter supplied by Conair, clean
it using water or air. Replace as needed.
5-10
MAINTENANCE
Series 1 Portable Chillers, PLC Control
UGH017/0500
All chillers are fully charged with refrigerant at the factory.
Your chiller’s model nameplate identifies the type and amount
of total refrigerant charge required.
WARNING: Refrigerant hazard
Only certified refrigerant technicians should
examine and correct problems involving the
refrigerant circuit.
CHECKING THE
REFRIGERANT
CHARGE
Check refrigerant charge while the chiller is running:
Check the refrigerant charge through the site
glass.
Use a flashlight, if necessary, and check the liquid-line
sight glass:
● Under full load conditions, the refrigerant should be
clear (no bubbles).
● Under low load conditions, when the hot-gas bypass
valves are operating, bubbles may be visible in the
sight glass. This is normal.
If the charge is low contact Conair service or have a local, certified refrigeration technician to add refrigerant to the system.
Sight
glass
UGH017/0500
Series 1 Portable Chillers, PLC Control
MAINTENANCE
5-11
CHECKING
RESERVOIR
LEVEL
WARNING: Electrical hazard
Before performing any work on this item, disconnect and lock out electrical power sources to
prevent injury from unexpected energization or
startup.
Check the fluid level in the reservoir. The meniscus in the
sight glass on the back of the chiller should be in line with the
mark on the sight glass.
To manually fill the reservoir:
1
2
Disconnect and lockout power to the chiller.
Locate the fill/drain valve
on the back of the chiller.
3
Refill the reservoir.
Monitor the level using the water level gauge on the back
of the chiller. Because the Portable Chiller can use either
pure water or a glycol solution, make sure your are
adding the correct fluid for your application.
Auto-fill port
Fill/Drain valve
Water level gauge
If you have the optional make-up water level float switch, it
will automatically control the fluid level.
5-12
MAINTENANCE
Series 1 Portable Chillers, PLC Control
UGH017/0500
TROUBLESHOOTING
● Before Beginning . . . . . . . . . . . .6-2
● A Few Words of Caution . . . . . .6-3
● Identifying the Cause
of a Problem . . . . . . . . . . . . . .6-3
● Answering Alarms . . . . . . . . . . .6-4
● Control Problems . . . . . . . . . . . .6-6
● Alarm Conditions . . . . . . . . . . . .6-8
● Checking and Replacing
Switches . . . . . . . . . . . . . . . .6-16
● Checking the Pressure
Transducer . . . . . . . . . . . . . . .6-17
● Checking the Temperature
Transmitter and RTD . . . . . . . .6-18
● Replacing the RTD . . . . . . . . . .6-20
● Replacing the Temperature
Transmitter . . . . . . . . . . . . . . .6-21
● Removing Pump Components .6-22
● Replacing Overload Modules .6-23
● Replacing Fuses . . . . . . . . . . .6-24
● Replacing the Contactor . . . . .6-25
● Replacing the PLC . . . . . . . . . .6-26
Series 1 Portable Chillers, PLC Control
UGH017/0500
6-1
BEFORE
BEGINNING
You can avoid most problems by following the recommended
installation, operation and maintenance procedures outlined in
this User Guide. If you have a problem, this section will help
you determine the cause and tell you how to fix it.
Before you begin troubleshooting:
❒ Find any wiring, piping, and assembly diagrams that
were shipped with your equipment. These are the best
reference for correcting a problem. The diagrams will
note any custom features or options not covered in this
User Guide.
❒ Verify that you have all instructional materials related
to the chiller. Additional details about troubleshooting
and repairing specific components are found in these
materials.
❒ Check that you have User Guides for the other equipment connected in the system. Troubleshooting may
require investigating other equipment attached to, or
connected with the chiller.
6-2
TROUBLESHOOTING
Series 1 Portable Chillers, PLC Control
UGH017/0500
WARNING: Improper installation, operation, or servicing may result in equipment damage or personal injury.
A FEW WORDS
OF CAUTION
This equipment should only be installed, adjusted, and serviced by qualified technical personnel who are familiar with the construction, operation, and potential hazards of this type of
machine.
All wiring, disconnects, and fuses should be
installed by qualified electrical technicians in
accordance with electrical codes in your region.
WARNING: Electrical hazard
Before performing any work on this item, disconnect and lock out electrical power sources to
prevent injury from unexpected energization or
startup.
WARNING: Refrigerant hazard
Only certified refrigerant technicians should
examine and correct problems involving the
refrigerant circuit.
CAUTION: Hot Surfaces
Always protect yourself from hot surfaces when
working on the Portable Chiller, especially when
working on or around the compressor and condenser. These devices can reach up to 160 °F
(71 °C). Allow these devices to cool before performing any maintenance or troubleshooting.
The Troubleshooting section covers problems directly related
to the operation and maintenance of the Portable Chiller.
Additional troubleshooting help can be found in the documentation manuals included with this User Guide.
Conditions you may see are:
IDENTIFYING
THE CAUSE OF
A PROBLEM
● electrical - a fuse out, a switch has tripped
● mechanical - pump, compressor, condenser fan(s) not
working
● physical - water flow incorrect
UGH017/0500
Series 1 Portable Chillers, PLC Control
TROUBLESHOOTING
6-3
When an alarm condition occurs, the display flashes the alarm
condition and the Alarm light on the control panel lights. Press
the Alarm Silence/ Reset button to acknowledge the alarm and
silence the optional audible alarm.
ANSWERING
ALARMS
Press the Alarm arrow on the Main screen:
STATUS
SETUP RUN ALM
press arrow
The most recent alarm displays on the screen.
SP
Setpoint temperature;
the desired temperature
of To Process fluid exiting the chiller
ALM
Alarm number
DP
Refrigerant discharge pressure
measured at the
compressor outlet.
ALM 4
DP 40
SP 45
SU 1
SU
Refrigerant suction
pressure measured at
the compressor inlet.
Tmp
Current temperature
of the To Process
fluid, in F
Tmp 23
3M
M
Number of minute
when the last alarm
occurred.
To view any other alarms press the Scroll arrows.
A screen displays for each alarm. Alarms are listed in order of
occurrence, starting with the most recent (check the Time
information on display).
6-4
TROUBLESHOOTING
Series 1 Portable Chillers, PLC Control
UGH017/0500
Use the Alarm table for a description of each alarm:
ANSWERING
ALARMS
CONT’D
Alarm No.
Alarm
Description
01
Low Tank Level
The fluid level in the pump tank is low.
02
Flow Fault
There is low flow of the process fluid at the pump
discharge.
03
Low Suction Pressure
The refrigerant pressure, as measured at the inlet
of the compressor is low.
04
High Discharge Pressure
The refrigerant pressure, as measured at the
compressor outlet is high.
05
Compressor Overload
There is a high amperage condition; the compressor is drawing too much current.
06
Pump Overload
There is a high amperage condition; the pump is
drawing too much current.
07
High Temperature Safety
The To Process fluid temperature is above 95 °F,
or the To Process fluid temperature is above 75 °F
after the compressor has been running for five
minutes at startup.
08
Low Temperature Cutout
If the To Process fluid temperature falls below the
low temperature cutout, the compressor shuts off
to allow the temperature to rise.
The alarm information remains on the screen until the alarm
condition is corrected. Press the Alarm Silence/Reset button to
acknowledge the alarm condition and to turn off the optional
audible alarm.
Refer to the Troubleshooting tables to troubleshoot the alarm
condition(s). After correcting the condition, remove the alarm
from the screen.
Press and hold the Alarm Silence/Reset button for a minimum
of 3 seconds to remove alarm from screen.
UGH017/0500
Series 1 Portable Chillers, PLC Control
TROUBLESHOOTING
6-5
CONTROL
PROBLEMS
Look here if the control panel is not lit, or if the power is on
and the Portable Chiller will not run.
Symptom
Possible cause
Solution
The control is not lit
and the chiller is not
working.
Power is not reaching the
chiller.
❐ Check the power cord and
plug. Make sure the cord and
plug are properly connected.
❐ Make sure the main disconnect switch is on.
❐ Check fuses and breakers.
Replace or reset as required.
See Replacing Fuses, in the
Troubleshooting section.
The correct power is not
reaching the unit
Check the voltage specification
on the chiller nameplate.
There is a problem with
the PLC.
❐ Check fuses and replace as
needed. See Replacing Fuses,
in the Troubleshooting section.
❐ Check the cable between the
control panel and the PLC;
reconnect or replace as needed.
❐ Check the PLC indicator
lights for normal status.
Contact Conair Service if status is not normal.
There is a problem with
the control panel.
6-6
TROUBLESHOOTING
The control panel may have
failed. Contact Conair Service.
Series 1 Portable Chillers, PLC Control
UGH017/0500
CONTROL
PROBLEMS
CONT’D
Symptom
Possible cause
Solution
The control is lit and
there is no alarm
condition. The compressor hums, but
does not run.
The input voltage is
incorrect
Check the main supply voltage. It must be within 10% of
the nameplate rating.
There is a phase loss.
❐ Check the fuses on the main
power supply. Replace or reset
as required.
❐ Check the phase-to-phase
voltages.
❐ Check phase continuity
through the compressor contactor.
❐ Check the wiring at the
compressor.
Repair or replace any of these
as needed.
UGH017/0500
Series 1 Portable Chillers, PLC Control
TROUBLESHOOTING
6-7
ALARM
CONDITIONS
6-8
Alarm
Possible cause
Solution
ALM 01
Low Water Tank
Level alarm
Process fluid level in tank
is low.
Fill tank to proper level. See
Checking Reservoir Level, in
the Maintenance section.
Inspect for leaks in the process
piping. Repair as necessary.
See Making Plumbing
Connections, in the Installation
section.
Failed Level switch.
Check pump level gauge on
the back of the chiller and
compare it to the status of the
level switch by checking continuity of switch in electrical
enclosure. Refer to wiring diagrams.
TROUBLESHOOTING
Series 1 Portable Chillers, PLC Control
UGH017/0500
ALARM
CONDITIONS
CONT’D
Alarm
Possible cause
Solution
ALM 02
Flow Fault alarm
The To Process and From
Process valves are closed.
Open/adjust valve(s).
The Process Fluid strainer is clogged.
Clean the strainer.
Process fluid level in
reservoir is low and float
switch failed.
Fill the reservoir. See Making
Process Plumbing
Connections, in the Installation
section.
The evaporator is fouled.
Clean Evaporator. See
Cleaning the Evaporator or
Water-cooled Condenser, in the
Maintenance section.
Pump is not running.
Check overload module. Reset
or replace as needed. See
Replacing Overload Modules,
in the Troubleshooting section.
Pump is running backwards; no pump pressure
is indicated on pump discharge pressure gauge.
Switch any two of the three
main power leads to the pump.
The evaporator is frozen.
Check for proper percentage of
glycol mixture; adjust as needed (see Setting Percent Glycol,
in the Operations section).
UGH017/0500
Series 1 Portable Chillers, PLC Control
TROUBLESHOOTING
6-9
ALARM
CONDITIONS
Alarm
Possible cause
Solution
ALM 03
Low Suction
Pressure alarm
No or low flow with a
failed flow switch and
RTD.
❐ Check To Process and From
Process valves to see if they
are open.
❐ Check Flow switch and
RTD. Replace as needed.
Compressor suction valve
is closed.
Open valve.
No load on the Chiller.
Compare process load to
required load. Chiller may be
oversized.
The Evaporator is fouled.
Clean Evaporator. See
Cleaning the Evaporator or
Water-cooled Condenser, in the
Maintenance section.
The evaporator is frozen.
❐ Check flow switch, RTD,
temperature transmitter and
low temperature cutout on
temperature controller.
Replace as needed.
❐ Check PLC control for
proper percent ethylene glycol or propylene glycol solution. Change percent glycol
setpoint, if needed.
There is a refrigerant
leak.
Check for oil in chiller cabinet
and bubbles in refrigerant sight
glass. Consult Conair Service
for repair.
Faulty pressure transduc- See Checking the Pressure
Transducer, in the
er.
Troubleshooting section.
6-10
TROUBLESHOOTING
Series 1 Portable Chillers, PLC Control
UGH017/0500
ALARM
CONDITIONS
CONT’D
Alarm
Possible cause
Solution
ALM 04
High Refrigerant
Discharge Pressure
alarm
Clogged/dirty air-cooled
condenser.
Clean the coil. See Cleaning
the Air-cooled Condenser, in
the Maintenance section.
Blocked air flow to aircooled condenser.
Move chiller or unblock air
passageway.
Low condenser water
flow or water too warm
to water-cooled condenser.
Check required flow; see
Specifications in the
Description section.
Blocked condenser water
line or valve closed.
Unblock line; open valve.
Condenser fouled.
Clean the condenser. See
Cleaning the Air-cooled
Condenser, and Cleaning the
Evaporator or Water-cooled
Condenser, in the Maintenance
section.
Compressor discharge
valve closed (if supplied).
Open valve.
Overcharged with refrigerant.
See Checking the Refrigerant
Charge, in the Maintenance
section.
Faulty water regulating
valve.
Repair or replace the valve.
Faulty pressure transduc- See Checking the Pressure
Transducer, in the
er.
Troubleshooting section.
Ambient air is over 95 °F.
UGH017/0500
Series 1 Portable Chillers, PLC Control
TROUBLESHOOTING
6-11
ALARM
CONDITIONS
6-12
Alarm
Possible cause
SOLUTION
ALM 05
Compressor
Overload alarm
Overload set incorrectly.
Check table on wiring diagram
for correct full load amperage
draw. Adjust overload accordingly.
Low supply voltage.
❏ Check supply voltage.
Supply voltage to contactor
should be +- 10% of nameplate voltage.
❏ Check wire terminations
and connections. Tighten if
loose.
Faulty contactor
Check line and load side of
contactor. There should be less
than a 5 volt drop across the
contactor. If there is not,
replace the contactor. See
Replacing the Contactor in the
Troubleshooting section.
Faulty overload module.
Check amp draw of circuit. If
it is under the rated setting,
replace the overload module.
See Replacing Overload
Modules, in the
Troubleshooting section.
TROUBLESHOOTING
Series 1 Portable Chillers, PLC Control
UGH017/0500
ALARM
CONDITIONS
CONT’D
Alarm
Possible cause
Solution
ALM 06
Pump Overload
alarm
Overload set incorrectly.
Check table on wiring diagram
for correct full load amperage
draw. Adjust overload accordingly.
Low supply voltage.
❏ Check supply voltage.
Supply voltage to contactor
should be +- 10% of nameplate voltage.
❏ Check wire terminations
and connections. Tighten if
loose.
Faulty contactor
Check line and load side of
contactor. There should be less
than a 5 volt drop across the
contactor. If there is not,
replace the contactor. See
Replacing the Contactor in the
Troubleshooting section.
Faulty overload module.
Check amp draw of circuit. If
it is under the rated setting,
replace the overload module.
See Replacing Overload
Modules, in the
Troubleshooting section.
UGH017/0500
Series 1 Portable Chillers, PLC Control
TROUBLESHOOTING
6-13
ALARM
CONDITIONS
CONT’D
Alarm
Possible cause
Solution
ALM 07
High Temperature
Safety alarm
The hot gas bypass valve
is not working properly
(possibly stuck open)
Shut isolation valve to the Hot
Gas Bypass solenoid. If the To
Process temperature starts to
go down, the solenoid valve is
faulty. Have a certified refrigeration technician replace the
solenoid valve.
Large swings in process load
The high deviation temperature is set too close to or temperature may cause this
the setpoint temperature. to happen. Check the settings
for the high deviation; reset.
See Changing High Deviation,
in the Operation section.
Process fluid is not flowing between the supply
outlet and return outlet.
Check for plugged pipes,
closed valves, or failed flow
switch.
The compressor is not
running.
Check to see if Compressor
light is lit on the control. If it
is not, check compressor overload in compressor terminal
box. Check power to compressor and power to compressor
contactor.
See Checking the Temperature
Failed RTD or
Temperature Transmitter. Transmitter and RTD in the
Troubleshooting section.
6-14
TROUBLESHOOTING
Series 1 Portable Chillers, PLC Control
UGH017/0500
ALARM
CONDITIONS
CONT’D
Alarm
Possible cause
Solution
ALM 08
Low Temperature
Cutout alarm
The hot gas bypass valve
is not working properly
(possibly stuck closed).
If the To Process temperature
starts to go down, the solenoid
valve is faulty. Have a certified
refrigeration technician replace
the solenoid valve.
Process fluid flow is
insufficient.
Check for plugged pipes,
closed valves, or failed flow
switch.
See Checking the Temperature
Transmitter and RTD, in the
Failed RTD or
Temperature Transmitter. Troubleshooting section.
RFI interference may
have altered PLC.
UGH017/0500
Install shielded thermocouples.
Check for high frequency drives near Chiller or two-way
radio use near Chiller. Remove
these devices.
Series 1 Portable Chillers, PLC Control
TROUBLESHOOTING
6-15
CHECKING AND
REPLACING
SWITCHES
WARNING: Electrical hazard
Before performing any work on this unit, disconnect and lock out electrical power sources to
prevent injury from unexpected energization or
startup.
The pump tank has one or two float switches. The float switch
(low level cutout) activates the Low Water Level alarm. There
is also a flow switch in the process fluid line to verify flow.
To replace a level or flow switch:
Always refer to the wiring
diagrams that came with
your chiller to locate specific
electrical components.
1
2
Disconnect and lockout power to the chiller.
3
Check the switch.
Open the electrical enclosure and locate the
connection for the correct switch on the terminal switch.
Refer to the wiring diagrams you received with your
chiller to find the correct terminals.
Check continuity within the switch and make sure it corresponds to the condition of the switch. Clean the switch
if needed.
4
Replace the switches as needed.
Drain the tank to replace the switch(es).
To check a flow switch:
1
2
Remove the electrical cover on the flow switch.
Slide the top of the switch housing over until
the N.O. (normally open) shows when electrical cover is
placed back on.
3
Replace electrical cover on flow switch.
Flow switch
Level switch
6-16
TROUBLESHOOTING
Series 1 Portable Chillers, PLC Control
UGH017/0500
WARNING: Coolant hazard
Refrigerant can cause freezing of skin. All proper precautions should be taken any time the
refrigerant system is worked on. Any adjustment
that involves the refrigerant should only be performed by a certified refrigeration technician.
CHECKING THE
PRESSURE
TRANSDUCER
The transducer produces a 0.5-4.5 VDC analog signal that is
read by the PLC, which relates it to a pressure, based on the
range of the transducer. To check and adjust the pressure
transducer:
1
Locate the pressure transducer.
Use the wiring diagrams that came with your chiller for
exact location. Location varies depending on size of your
chiller.
2
Check the connections.
Always refer to the wiring diagrams you received with your
chiller to locate specific electrical components.
Make sure all connections to the transducer are secure.
Tighten as needed.
3
Check the supply voltage to the transducer.
Voltage should be 5VDC. Refer to the wiring diagram for
the exact location.
4
Check the control signal in the electrical panel
5
Check the transducer with a gauge.
if the supply voltage is correct (step 3). Refer to the
wiring diagram for the exact location. If the signal is outside the 0.5-4.5 VDC range replace the transducer.
If the reading is within the 0.5-4.5 VDC range, test the
line with a refrigeration gauge. Compare this number with
the reading on the Control screen. To get to the proper
screen on the control, from the main screen, press Status.
Use the scrolling arrows to move to the Suction Pressure
or Discharge Pressure screen. If the gauge and PLC
screen readings are not within 5% of each other, replace
the transducer.
Pressure
Transducer
UGH017/0500
Series 1 Portable Chillers, PLC Control
TROUBLESHOOTING
6-17
CHECKING THE
TEMPERATURE
TRANSMITTER
AND RTD
Always refer to the wiring
diagrams that came with
your chiller to locate specific
electrical components.
WARNING: Electrical hazard
Before performing any work on this unit, disconnect and lock out electrical power sources to
prevent injury from unexpected energization or
startup.
The Conair Portable Chiller uses a standard 100 ohm RTD to
monitor process temperature. A transmitter is also included
and is located in the temperature transmitter electrical box.
To check the temperature transmitter and RTD:
1
2
Disconnect and lockout power to the chiller.
Open the electrical enclosure.
Check wire connections at the terminals. Refer to the
wiring diagram.
3
4
Find the temperature sensor in the evaporator.
Check the wiring and connections
from the sensor to the temperature transmitter electrical
box.
5
6
Turn the power on to the chiller control.
Check the voltage, resistance and amperage.
Temperature
transmitter
electrical box
RTD
Evaporator
6-18
TROUBLESHOOTING
Series 1 Portable Chillers, PLC Control
UGH017/0500
CHECKING THE
TEMPERATURE
TRANSMITTER AND
RTD
CONT’D
OHMS
VOLTS
Temperature
transmitter board
CURRENT
Temperature
transmitter board
+
+
Temperature
transmitter board
RTD
-
+
black
black
RTD
-
red
black
red
Ohm
meter
Volt
meter
RTD
sensor
Power
supply
red
Current
meter
To
Controller
Problem
Possible cause
Solution
No reading
No power to board.
Check voltage at power supply. Measure volts across the +
and - of the power wires. Voltage should be 8 - 35 VDC.
Reading too low
RTD wires shorted.
Disconnect RTD before testing sensor resistance. Check
RTD with ohmmeter. Should be close to 100 ohms.
Improper range of transmitter (too low).
Disconnect black lead (-) and place current meter in series.
Check RTD with current meter. Current should be 4 -20
mA.
Condensation on board.
Inspect for condensation. Dry with hot air.
RTD opened.
RTD opened. Disconnect RTD before testing sensor resistance. Check RTD with ohmmeter. Should be close to 100
ohms.
Improper range of transmitter (too high).
Disconnect black lead (-) and place current meter in series.
Check RTD with current meter. Current should be 4 -20
mA.
Condensation on board.
Inspect for condensation. Dry with hot air.
Input power not clean.
Use twisted wires or shielded cable. RF resistant power
supply. Use a shielded cable to connect the sensor.
Connect the shield to ground. Encase the board in a RF
shielded enclosure.
Reading too high
RF Interference
UGH017/0500
Series 1 Portable Chillers, PLC Control
TROUBLESHOOTING
6-19
REPLACING THE
RTD
To replace the RTD:
1
2
Disconnect and lockout power to the chiller.
Disconnect the To Process tubing from the
To Process connection.
Fill/Drain valve
To Process
connection
3
Open the Drain/Fill valve and drain water
from the unit so the water level is lower that the RTD.
Always refer to the wiring diagrams you received with your
chiller to locate specific electrical components.
4
5
Open the side of the chiller.
Disconnect the RTD wiring from the
transmitter electrical box. Refer to the wiring diagram.
6
Remove the RTD.
Loosen the compression nut to slide the RTD out of the
evaporator.
7
Install the new RTD.
The new RTD should be inserted in the evaporator so that
the tip is extended completely through the evaporator.
8
Wire the RTD to the temperature transmitter
and to the electrical box.
Temperature
transmitter
electrical box
RTD
6-20
TROUBLESHOOTING
Series 1 Portable Chillers, PLC Control
UGH017/0500
To replace the temperature transmitter:
1
2
3
Disconnect and lockout power to the chiller.
Open the side of the chiller.
REPLACING THE
TEMPERATURE
TRANSMITTER
Disconnect the RTD wiring from the
transmitter electrical box. Refer to the wiring diagram.
4
Disconnect transmitter wiring from main
electrical panel.
5
Remove the temperature transmitter electrical
box and wiring.
6
7
Install the new temperature transmitter.
Thread the leads of the temperature
Always refer to the wiring diagrams you received with your
chiller to locate specific electrical components.
transmitter through the cabinet leading to the temperature
transmitter electrical box. Wire the temperature transmitter (see wiring diagram).
Temperature
transmitter
electrical box
RTD
UGH017/0500
Series 1 Portable Chillers, PLC Control
TROUBLESHOOTING
6-21
REMOVING
PUMP
COMPONENTS
The pump’s wet end (impeller, motor, and seal assembly) can
be removed for service.
1
2
Disconnect and lockout power to the chiller.
Open the drain/fill valve and
drain the water from the chiller.
Open
this
side
3
4
Fill/Drain valve
Open the side of the chiller.
Remove the bolts connecting the pump
assembly to the pump housing.
5
Remove the pump assembly.
Carefully slide it sideways away from the pump tank to
avoid damage.
6
Inspect, clean, and replace pump parts
as needed. Separate the pump assembly from the pump
volute (casing) by prying the flanges and pulling apart.
Follow the disassembly and reassembly procedures in the
pump manufacturer’s manual that accompanies this User
Guide.
6-22
TROUBLESHOOTING
Series 1 Portable Chillers, PLC Control
UGH017/0500
WARNING: Electrical hazard
Before performing any work on this unit, disconnect and lock out electrical power sources to
prevent injury from unexpected energization or
startup.
REPLACING
OVERLOAD
MODULES
Normally if the overload trips, resetting the overload and correcting the cause is typically all that is needed. However, if the
overload continues to trip, it may be necessary to replace the
overload module.
To replace the overload module:
1
2
3
Disconnect and lockout power to the chiller.
Open the electrical enclosure.
Locate the overload module and disconnect
Always refer to the wiring diagrams you received with your
chiller to locate specific electrical components.
the power leads from the module to the device. Refer to
the wiring diagram for the exact location. Note the placement of each lead and label as needed.
4
5
6
Disconnect auxiliary wiring to the module.
Loosen the screws and remove the module.
Install the new module
and tighten in place with the screws.
7
8
Reconnect wires and leads.
Adjust setting to correct Full Load Amps
rating of compressor, fan or pump.
9
Restore power to the chiller.
Pump overload
module (MSP2)
Compressor overload module (MSP1)
UGH017/0500
Series 1 Portable Chillers, PLC Control
TROUBLESHOOTING
6-23
REPLACING
FUSES
WARNING: Electrical hazard
Before performing any work on this unit, disconnect and lock out electrical power sources to
prevent injury from unexpected energization or
startup.
To replace fuses:
1
2
Always refer to the wiring
diagrams you received with
your chiller to locate specific electrical components.
Disconnect and lockout power to the chiller.
Open the electrical enclosure and locate
the fuses. Refer to the wiring diagram for the exact location.
3
4
Remove and replace fuses.
Restore power to the chiller.
Control transformer
primary fuses
Control transformer
secondary fuses
Crankcase
heater fuses
6-24
TROUBLESHOOTING
Series 1 Portable Chillers, PLC Control
UGH017/0500
WARNING: Electrical hazard
Before performing any work on this unit, disconnect and lock out electrical power sources to
prevent injury from unexpected energization or
startup.
REPLACING THE
CONTACTOR
To replace contactor for the pump or compressor:
1
2
Disconnect and lockout power to the chiller.
Open the electrical enclosure and locate
the correct contactor. Refer to the wiring diagrams you
received with your chiller.
3
Disconnect the wiring from the contactor.
Always refer to the wiring
diagrams that came with
your chiller to locate specific
electrical components.
Make sure you label each wire so you can correctly install
the new unit.
4
Remove the contactor by snapping off
the DIN rail mounting.
5
Snap in the new contactor on the DIN rail.
6
Reconnect the wiring and reconnect power
to the chiller.
Fan 2
contactor (M4)
Fan 1
contactor (M3)
Pump contactor
(M2)
Compressor
contactor (M1)
UGH017/0500
Series 1 Portable Chillers, PLC Control
TROUBLESHOOTING
6-25
REPLACING THE
PLC
WARNING: Electrical hazard
Before performing any work on this unit, disconnect and lock out electrical power sources to
prevent injury from unexpected energization or
startup.
NOTE: Contact your Conair Service representative before
replacing the PLC.
Always refer to the wiring diagrams you received with your
chiller to locate specific electrical components.
1
2
3
Disconnect and lockout power to the chiller.
Open the top electrical enclosure.
Unplug connectors from the back of the PLC
by pulling them straight off.
4
5
Loosen the screws holding the PLC
Remove the PLC and shield from the
enclosure as a single unit.
6
7
8
Place new PLC into position.
Tighten the screws to hold the PLC in place.
Replace connectors.
The PLC is preprogrammed at the factory. You can tell if the
PLC is programmed if it displays the chiller model on the display screen when it powers up. If this does not happen, contact your Conair Service representative.
Conair Chiller
A1 - 5
6-26
TROUBLESHOOTING
Series 1 Portable Chillers, PLC Control
UGH017/0500
Conair has made the largest investment in customer support in
the plastics industry. Our service experts are available to help
with any problem you might have installing and operating
your equipment. Your Conair sales representative also can help
analyze the nature of your problem, assuring that it did not
result from misapplication or improper use.
WE’RE HERE
TO HELP
To contact Customer Service personnel, call:
HOW TO CONTACT
CUSTOMER
SERVICE
From outside the United States, call: 814-437-6861
You can commission Conair service personnel to provide onsite service by contacting the Customer Service Department.
Standard rates include an on-site hourly rate, with a one-day
minimum plus expenses.
If you do have a problem, please complete the
following checklist before calling Conair:
❒ Make sure you have all model, serial and parts list
numbers for your particular equipment. Service
personnel will need this information to assist you.
BEFORE YOU
CALL ...
❒ Make sure power is supplied to the equipment.
❒ Make sure that all connectors and wires within
and between control systems and related
components have been installed correctly.
❒ Check the troubleshooting guide of this manual
for a solution.
❒ Thoroughly examine the instruction manual(s)
for associated equipment, especially controls.
Each manual may have its own troubleshooting
guide to help you.
❒ Check that the equipment has been operated as
described in this manual.
❒ Check accompanying schematic drawings for
information on special considerations.
IMS0002/0296
SERVICE INFORMATION
Additional manuals and
prints for your Conair
equipment may be
ordered through the
Customer Service or
Parts Departments for
a nominal fee.
APPENDIX A-1
EQUIPMENT
GUARANTEE
Conair guarantees the machinery and equipment on this
order, for a period as defined in the quotation from date of
shipment, against defects in material and workmanship
under the normal use and service for which it was recommended (except for parts that are typically replaced after
normal usage, such as filters, liner plates, etc.). Conair’s
guarantee is limited to replacing, at our option, the part or
parts determined by us to be defective after examination.
The customer assumes the cost of transportation of the
part or parts to and from the factory.
PERFORMANCE
WARRANTY
Conair warrants that this equipment will perform at or
above the ratings stated in specific quotations covering the
equipment or as detailed in engineering specifications,
provided the equipment is applied, installed, operated and
maintained in the recommended manner as outlined in our
quotation or specifications.
Should performance not meet warranted levels, Conair at
its discretion will exercise one of the following options:
● Inspect the equipment and perform alterations or
adjustments to satisfy performance claims. (Charges
for such inspections and corrections will be waived
unless failure to meet warranty is due to misapplication, improper installation, poor maintenance practices
or improper operation.)
● Replace the original equipment with other Conair
equipment that will meet original performance claims
at no extra cost to the customer.
● Refund the invoiced cost to the customer. Credit is
subject to prior notice by the customer at which time a
Return Goods Authorization Number (RGA) will be
issued by Conair’s Service Department. Returned
equipment must be well crated and in proper operating
condition, including all parts. Returns must be prepaid.
Purchaser must notify Conair in writing of any claim and
provide a customer receipt and other evidence that a claim
is being made.
WARRANTY
LIMITATIONS
A-2
APPENDIX
Except for the Equipment Guarantee and Performance
Warranty stated above, Conair disclaims all other warranties with respect to the equipment, express or
implied, arising by operation of law, course of dealing,
usage of trade or otherwise, including but not limited to
the implied warranties of merchantability and fitness for
a particular purpose.
WARRANTY INFORMATION
IMS0003/0796
MAINTENANCE
LOG
Date
Reading
Maintenance Item
Compressor Amps,
100% loaded
Discharge Pressure
Suction pressure
Evaporator water out
temperature
Process Water Pressure,
In/Out
Condenser Water
Temperature, In/Out
Condenser Water
Pressure, In/Out
Condenser Fan Amps (1)
Condenser Fan Amps (2)
Pump Amps
Unit Volts
Primary
Secondary
Condenser Air Temp In
Condenser Air Temp Out
Oil Level
Super Heat
Temperature Setpoint
UGH017/0500
Series 1 Portable Chillers, PLC Control
APPENDIX B-1
PRESSURE
TABLES
Evaporator and Piping
Pressure Drops
Pressure Drop, PSID
A1/W1-2
A1/W1-1.5
A1/W1-3
A1/W1-7.5
A1/W1-10, A1-13
A1/W1-4
A1/W1-5
W1-15
Flow Rate, GPM
UGH017/0500
Series 1 Portable Chillers, PLC Control
APPENDIX C-1
Condenser and Piping
Pressure Drops
PRESSURE
TABLES
80
W1-1.5
W1-2
Pressure Drop, PSID
70
W1-3
W1-7.5
W1-4
60
W1-5
W1-10
W1-15
50
40
30
20
10
0
0
5
10
15
20
25
30
35
40
45
50
55
Flow Rate, GPM
APPENDIX C-2
Series 1 Portable Chillers, PLC Control
UGH017/0500
SCOT MOTORPUMP™
J56 & JM FRAME
STRAIGHT CENTRIFUGAL
304 STAINLESS STEEL
l INSTALLATION l OPERATION l MAINTENANCE
INCLUDES
MECHANICAL
SEAL
REPLACEMENT
Check pump for shortage and damage immediately upon
arrival. Note damage or shortage on freight bill (bill of
lading); immediately file claim with carrier.
EXTERIOR — Pay particular attention to conduit box,
external hardware and accessories. Touch up abrasions
or scratches with approved paint.
INTERNAL — If extensive or serious external damage
is noted, if impeller is damaged (look in ports), or if shaft
binds or sticks, disassemble as required to permit
internal inspection.
HANDLING
Handle with care. Dropping or jarring can seriously
damage motor bearings or break pump parts. Lift with
device having capacity for pump weight, and use lifting
hooks or eye bolts (if provided) or rig double sling around
motor frame and pump casing. Do not use sling through
pump motor adapter nor around suction and discharge
flanges.
INSTALLATION
Location — Pump location should provide the
following:
1. Install as close to suction supply as possible.
2. Shortest and most direct suction pipe practical.
Suction lift must not exceed limit for pump. NPSH
available must equal or exceed pump requirement.
3. Suction port below pumping level to provide priming.
4. Room for inspection and maintenance.
5. Correct power supply to motor; all wiring should
meet National Electrical and Local Codes and
Regulations.
6. If outdoors, protection from the elements, freezing
and water damage due to flooding.
Piping — Suction and discharge gauges are useful to
check pump operation and are excellent trouble
indicators. Install gauges in the lines if pump ports do
not have gauge taps. Observe these precautions when
installing piping:
1. Support close to, but independently of pump.
2.
3.
4.
5.
6.
Use the next larger pump size for suction
and discharge.
Keep as straight as possible. Avoid bends
and fittings.
Remove burrs, sharp edges, ream pipe cuts, and
make joints air-tight.
Don’t spring pipe to make connections.
Strain must not be transmitted to pump.
Allow for pipe expansion with hot fluids;
expansion joints are not recommended.
Suction — Size and install suction piping to keep
pressure loss at minimum and to provide correct NPSH
by observing the following:
1. The suction pipe should be equal in size or
preferably one size larger than the suction
connection of the pump. If pipe is larger than the
pump suction, an eccentric pipe reducer should be
used at the pump.
2. Pipe should slope upward to pump, even for
horizontal run.
3. Use 45-degree or long-sweep 90-degree elbows.
4. A valve in the suction is necessary only on positive
suction head installation and must not be used to
throttle the pump. The suction valve should be
installed for maintenance purposes only.
Discharge — Pumps permit discharge port location
at any of four positions, 90 degrees apart. Change by
removing cover bolts, rotate casing, and replace bolts.
Do not slice O-ring or tear fibre gasket. Scot does not
recommend bottom vertical discharge due to erratic
pump performance. Ensure there is adequate clearance
with selected position between wall or tank, motor
conduit box, and grease fittings. Casing may extend
beyond base or feet.
1. Short discharge lines may be the same size as the
discharge port. Long runs require a pipe larger
than the discharge port.
2. Long horizontal runs require a grade as even as
possible. Avoid high spots and loops. Trapped air
will throttle flow and may result in erratic pumping.
3. Install check and gate valves in discharge line;
check valve (if used) between pump and gate valve.
SCOT DIVISION OF ARDOX CORP. — HOME OFFICE
• Cedarburg, WI 53012
• P.O. Box 286
• 262-377-7000
• FAX 262-377-7330
• 949-756-8076
• 954-524-6776
• FAX 949-756-9480
• FAX 954-764-3361
FACTORY BRANCHES
• Irvine, CA 92614
• Ft. Lauderdale, FL 33315
• 1881 Kettering
• 77 SW 20th Street
61.000.281
JANUARY 2000
OPERATION
Pre-Start — Before initial start of the pump, check as
follows:
1. The rotation must be checked upon installation.
Close, then break the contacts quickly and observe
the rotation of the exposed portion of the rotating
parts. Rotation must agree with the rotation arrow
on the motor. For all pumps, the standard rotation is
counterclockwise when viewed from the suction
end. Motor wiring is easily changed in the field.
Observe the wiring diagram on the inside of the
terminal box cover, or on the motor nameplate.
2. Check voltage, phase and frequency of line circuit
with motor nameplate.
3. Check suction and discharge piping and
pressure gauges for proper operation.
4. Assure that pump is full of liquid (primed).
Priming — If pump is installed with a positive head
on the suction, prime by opening suction valve and
allowing liquid to enter the casing, at the same time
venting all air out of the top of the casing.
If pump is installed with a suction lift, priming must be
done by other methods, such as foot valves, ejectors, or
by manually filling casing and suction line.
CAUTION - DO NOT RUN PUMP DRY. Serious damage
may result if started dry.
Starting — Proceed as follows to start pump:
1.
2.
3.
4.
5.
6.
Close drain valves and valve in discharge line.
Open fully all valves in the suction line.
Prime the pump. If pump does not prime properly,
or loses prime during start-up, shut down and
correct condition before repeating procedure.
For pumps moving high temperature liquids,
open warm-up valve to circulate liquid for
preheating. Close valve after pump has warmed up.
Start the motor (pump).
When pump is operating at full speed, open
discharge valve slowly.
Running — Periodically inspect pump while running,
but especially after first start and following repair.
1. Check pump and piping for leaks.
Repair immediately.
2. Record pressure gauge readings for future reference.
3. Record voltage, amperage per phase, and kW
(if an indicating wattmeter is available).
4. Adjust pump output capacity with discharge valve.
DO NOT throttle suction line.
Temperature — Total temperature, not the rise, is the
measure of safe operation for a motor. If temperature by
thermometer exceeds limits for insulation class,
investigate and change operating conditions.
Labeled Motors — It is imperative for repair of a
motor with Underwriters’ Laboratories label that original
clearances be held; that all plugs, screws, other
hardware be fastened securely, and that parts
replacements be exact duplicates or approved equals.
Violation of any of the above invalidates Underwriters’
label.
Lubrication
—
Pumps should require no
maintenance, other than the motor bearings,
according to the following instructions:
DOUBLE SHIELDED.
When double shielded
prelubricated bearings are furnished, no lubrication is
required for the life of the bearings. Inspect bearings
periodically to determine the condition of the grease and
replace the bearings if necessary.
SINGLE SHIELDED W/GREASE FITTING PROVISIONS.
When single shield bearings are furnished, periodic
inspection, cleaning and relubrication is required. See
motor manufacturer’s specific instructions for
lubrication.
MECHANICAL SEAL REPLACEMENT
J56 FRAME MOTOR
A.)
Disassembly:
1. Turn off power.
2. Close suction and discharge valves.
3. Drain pump.
4. Remove bolts holding base to foundation
5. Remove casing bolts.
6. Remove motor and rotating element
from casing, leaving casing and piping
undisturbed.
7. Insert a screwdriver in one of the impeller
waterway passages and back off the
impeller nut as shown in Figure 1.
Freezing Protection — Protect pumps shut down
during freezing conditions by one of the following
methods:
1. Drain pump; remove all liquid from the casing.
2. Keep fluid moving in pump and insulate or heat
the pump to prevent freezing. If heated, do not let
temperature go above 100 to 150 degrees F.
3. Fill pump completely with antifreeze solution.
MAINTENANCE
Cleaning — Remove oil , dust, dirt, water, chemicals
from exterior or motor and pump. Keep motor air inlet
and outlet open. Blow out interior of open motors with
clean compressed air at low pressure. Regularly drain
moisture from TEFC motors.
Figure 1
8. Remove motor shaft end cap. Insert a
screwdriver in slot of motor shaft. While
holding shaft against rotation, unscrew
impeller from shaft by turning
counterclockwise when facing impeller
(Figure 2).
9. Pry off rotating member of mechanical seal
from motor shaft by using (2) screwdrivers.
Be careful not to damage the pump cover.
See Figure 3.
5. Hold shaft against rotation as described in
paragraph 8 of disassembly procedure, and
thread impeller on shaft until it is tight
against the shaft shoulder. The impeller will
compress the seal spring to the proper
length assuring correct pressure on lapped
faces.
6. Replace D-washer and impeller nut holding
impeller against rotation as indicated in
paragraph 7 of disassembly procedure
(2 & 3 HP 1PH, and all 3PH motors only).
7. Remove any burrs caused by screwdriver on
the vane of impeller in waterway passage.
8. Replace motor and rotating element in
casing. Be sure that any damaged O-ring is
replaced.
9. Position case, cover and motor disc so that
the holes line up. Install socket head cap
screws through the case and cover, and
thread into motor disc. Tighten all cap
screws alternately and evenly until finger
tight.
10. Finish tightening the cap screws
alternately and evenly to approximately 20
ft. lbs. torque. Note: It is imperative that the
screws be tightened alternately and evenly,
as this action centers the cover in the
casing, assuring proper alignment. Binding
of the impeller in the case and adapter may
occur if the cap screws are not tightened as
listed above.
11. Replace hold-down bolts.
12. Check for free rotation after assembly is
completed.
13. Replace motor shaft end cap.
14. Seal all drain openings using pipe sealant
on threads.
15. Reprime before starting. Do not start until
pump is completely filled with water.
Figure 2
Figure 3
10. Remove pump cover from cast iron disc.
(There is no hardware used to attach cover
to disc.) Place cover on a flat surface with
convex side down. Push out stationary
member of mechanical seal. It is not
necessary to remove the cast iron disc from
the motor to replace the seal.
B.)
Reassembly:
CAUTION: The mechanical seal is a
precision product and should be handled
accordingly. Use care when handling lapped
running surfaces of the mechanical seal to
ensure they remain clean and are free of
chips or scratches.
1. Clean gasket and flange faces, seal seat
cavity and shaft, in particular shaft shoulder
fitting against impeller.
2. Lubricate the seal seat cavity of the cover
and the rubber cup or O-ring of stationary
seal seat with the lubricating fluid that
comes with the mechanical seal or repair kit.
Press the stationary seat in seal seat cavity
in the cover squarely and evenly using a
arbor press (if possible) and the cardboard
disc supplied with the seal. Be certain that
the lapped face (shiny side) is facing you.
3. Position the cover so that the convex side
with the lapped seal seat is facing you.
Place the cover on the motor disc and align
the holes in the disc with the holes in the
cover. (Note: There isn’t any hardware
required to attach the cover to the motor
disc.)
4. Apply the lubricating fluid that comes with
the mechanical seal or repair kit to the motor
shaft and the rubber bellows of the rotary
seal. Slide the seal head on the shaft, press
the rubber drive band on the rotary head
until the lapped face on the head seats
firmly against the lapped face of the
stationary seat. Install seal spring on head
and seal spring retainer on spring. Do not
chip or scratch faces during installation.
Take extra care to make sure the lapped
faces are clean.
MECHANICAL SEAL REPLACEMENT
JM FRAME MOTOR
A.)
Disassembly:
1. Turn off power.
2. Close suction and discharge valves.
3. Drain pump.
4. Remove bolts holding down pump to
mounting plate.
5. Remove casing bolts.
6. Remove motor and rotating element
from casing, leaving casing and piping
undisturbed.
Figure 4
7. Insert a screwdriver in one of the impeller
waterway passages and back off the
impeller retaining assembly with a
socket wrench, as shown in Figure 4.
8. Remove impeller from shaft, being careful
not to lose the impeller key, spring and
gasket. If impeller is difficult to remove, it
may be necessary to use a bearing puller to
remove.
5. Position the cover so that the convex side is
facing you and install on cast iron motor
disc. (There isn’t any hardward required to
attach cover to motor disc.)
6. Apply the lubricating fluid that comes with
the mechanical seal or repair kit to the motor
sleeve and the rubber bellows of the rotary
seal. Slide the seal head on the shaft sleeve,
press the rubber drive band on the rotary
head until the lapped face on the head seats
firmly against the lapped face of the
stationary seat. Do not chip or scratch faces
during installation. Take extra care to make
sure the lapped faces are clean.
7. Install nylon washer on shaft sleeve and seal
spring on seal head.
8. Place key in key seat. Line up keyway in
impeller with key on motor shaft, and slide
impeller on motor shaft. Be certain that the
key is positioned in the keyway of the motor
and impeller. Slightly compress seal spring
with impeller (making sure the seal spring is
positioned over stud on back of impeller),
and hold impeller while installing impeller
retaining assembly in motor shaft. Make
sure the nylon washer is installed on retaining nut.
9. Insert a screwdriver in a waterway passage
of the impeller holding it against rotation
and tighten impeller retaining assembly as
discussed in paragraph 7.
10. Remove any burrs caused by screwdriver on
the vane of impeller in waterway passage.
11. Slide motor and rotating element in casing.
Be sure that any damaged O-ring or gasket
is replaced.
12. Tighten casing bolts alternately and evenly.
13. Replace hold-down bolts.
14. Check for free rotation after assembly is
completed.
15. Close all drain openings, using pipe sealant
on threads.
16. Reprime before starting. Do not start unit
until pump is completely filled with water.
Figure 5
9. Pry off rotating member of mechanical seal
from sleeve by using two (2) screwdrivers.
Be careful not to damage the pump
cover. See Figure 5.
10. Remove pump cover from cast iron disc.
(There isn’t any hardware used to attach
cover to disc. Place cover on flat surface
with convex side down, and push out
stationary member of mechanical seal. It is
not necessary to remove cast iron disc from
motor to replace seal.
11. Inspect shaft sleeve and nylon washers. If
damaged or worn, remove from shaft and
replace.
A.)
Reassembly:
CAUTION: The mechanical seal is a
precision product and should be handled
accordingly. Use care when handling lapped
running surfaces of the mechanical seal to
ensure they remain clean and are free of
chips or scratches.
1. Clean gasket and flange faces, seal seat
cavity, shaft sleeve, and motor shaft.
2. Position cover so that the convex side is
facing you. Lubricate the seal seat cavity of
the cover and the rubber cup or O-ring of
seal seat with the lubricating fluid that
comes with the mechanical seal or repair kit.
Press the stationary seat in seal seat cavity
of the cover squarely and evenly using a
arbor press (if possible) and the cardboard
disc supplied with the seal. Be certain that
the lapped face (shiny side) is facing you.
3. Install nylon washer on motor shaft until
it bottoms on the motor shaft.
4. Install sleeve on motor shaft.
PUMP
NO.
68, 69
51, 61, 74
71, 72, 77, 78, 79, 82
11, 13, 60
62
ALL OTHERS
N/A-NOT AVAILABLE
The approved lubricating fluid for seal
installation is included with the mechanical
seal or repair kit. DO NOT USE OTHER
LUBRICATING LIQUIDS!
WE RECOMMEND STOCKING A SPARE
MECHANICAL SEAL OR REPAIR KIT
TO ELIMINATE DOWN TIME.
PRESSURE AND TEMPERATURE LIMITATION
STANDARD FITTED PUMPS
PRESSURE
TEMPERATURE
STANDARD
75 PSI
75 PSI
75 PSI
75 PSI
165 PSI
175 PSI
OPTIONAL
STANDARD
OPTIONAL
N/A
150 PSI
N/A
150 PSI
165 PSI
175 PSI
220°F
220°F
220°F
220°F
220°F
220°F
275°F
275°F
275°F
275°F
275°F
275°F
CAUTION
DO NOT ALLOW EITHER THE DISCHARGE PRESSURE OR THE TEMPERATURE OF THE LIQUID TO
EXCEED THE LIMITATIONS LISTED ABOVE.
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