110-279 DuraChill Chillers 5-10HP 6-10-2015 · Operator’s Manual ... 14 Signal Inputs ... Chiller...

Operator’s Manual DuraChill™ Air- and Water-Cooled Chillers

5, 7.5 and 10 HP

110-279 10 June 2015

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Table of Contents Introduction............................................................................................................................................................ 4

Standard and Optional Features ......................................................................................................................... 4 Standard Features ........................................................................................................................................... 4 Optional Features............................................................................................................................................. 4

General Safety Information.................................................................................................................................. 5 Safety Recommendations.................................................................................................................................... 6 Regulatory Compliance and Testing ................................................................................................................... 7 Unpacking............................................................................................................................................................ 7

Controls and Components ................................................................................................................................... 8 Control System .................................................................................................................................................... 8

Control Panel ................................................................................................................................................... 8 Power Switch / Disconnect .............................................................................................................................. 8 Temperature Probe.......................................................................................................................................... 8 Flow Sensor ..................................................................................................................................................... 8 Flow Switch ...................................................................................................................................................... 8 Fluid Pressure Sensor ..................................................................................................................................... 8 Refrigerant Pressure Switches ........................................................................................................................ 8 Fan Cycling Switch........................................................................................................................................... 9 Reservoir Float Switch (Optional) .................................................................................................................... 9

Fluid Circulation System...................................................................................................................................... 9 Evaporator........................................................................................................................................................ 9 Reservoir Tank................................................................................................................................................. 9 Sight Glass or Level Indicator .......................................................................................................................... 9 Pump................................................................................................................................................................ 9 Internal Bypass ................................................................................................................................................ 9 Y-Strainer ......................................................................................................................................................... 9 External Bypass / Shutoff Valves..................................................................................................................... 9 Process Side Stream Filter System (Optional) ................................................................................................ 9

Cooling System.................................................................................................................................................... 9 Common Cooling System Components........................................................................................................... 9 Evaporator...................................................................................................................................................... 9 Compressor.................................................................................................................................................... 9 Filter Dryer...................................................................................................................................................... 9 Sight Glass ..................................................................................................................................................... 9 Thermostatic Expansion Valve (TXV) ............................................................................................................ 9 Hot Gas Bypass Solendoid Valve ................................................................................................................ 10 Refrigerant Safety Relief Valve .................................................................................................................... 10

Air-Cooled Chillers (DA Models) .................................................................................................................... 10 Condenser.................................................................................................................................................... 10 Condensing Fan........................................................................................................................................... 10

Water-Cooled Chillers (DW Models).............................................................................................................. 10 Brazed Plate Heat Exchanger / Condenser ................................................................................................. 10 Condensing Water Regulating Valve ........................................................................................................... 10 Receiver ....................................................................................................................................................... 10

Component Identification................................................................................................................................... 11 Front - All Models ........................................................................................................................................... 11 5 HP and 7.5 HP Chillers - Rear .................................................................................................................... 11 10 HP Chillers - Rear ..................................................................................................................................... 12

Installation and Startup ...................................................................................................................................... 13 Site Requirements ............................................................................................................................................. 13

Ambient Temperature and Relative Humidity ................................................................................................ 13 Location.......................................................................................................................................................... 13 Clearance....................................................................................................................................................... 13

Electrical Power ................................................................................................................................................. 14 Signal Inputs/Outputs ........................................................................................................................................ 15

Remote On / Off ............................................................................................................................................. 15

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Alarm Output .................................................................................................................................................. 15 RS-232/RS-485 Serial Output........................................................................................................................ 15

External Piping................................................................................................................................................... 16 General Considerations ................................................................................................................................. 16 Process Fluid Connections ............................................................................................................................ 16 Facility Water Connections ............................................................................................................................ 16 Reservoir Drain .............................................................................................................................................. 16 Reservoir Vent ............................................................................................................................................... 16 Internal Bypass .............................................................................................................................................. 17

Process Coolant ................................................................................................................................................ 18 Suitable Fluids................................................................................................................................................ 18

Startup ............................................................................................................................................................... 19 Facility Water Flow (water-cooled units only) ................................................................................................ 19 Filling the Reservoir ....................................................................................................................................... 19 Starting Process Fluid Flow ........................................................................................................................... 20

Normal Operation ................................................................................................................................................ 21 Power On........................................................................................................................................................... 21 Temperature Unit (°C or °F) Selection / Factory Default Reset ........................................................................ 21 Adjusting the Set Point Temperature................................................................................................................. 22 Selecting the Pressure / Flow Rate Display and Units ...................................................................................... 22 Displaying Internal (P1) and External (P2) Probe Temperatures...................................................................... 22 Setting Operational Parameters / Limits............................................................................................................ 22

High Temperature Limit (HL) ......................................................................................................................... 25 Low Temperature Limit (LL)........................................................................................................................... 25 High Ambient Temperature Limit (HA)........................................................................................................... 26 Maximum Fluid Pressure (FP) ....................................................................................................................... 26 Minimum Flow Rate (FL)................................................................................................................................ 26 Lower Band (Lb)............................................................................................................................................. 27 Upper Band (Ub) ............................................................................................................................................ 27 Remote Probe (rP) ......................................................................................................................................... 27 Calibration Offset (C1 / C2 / C3) .................................................................................................................... 27 Compressor Delay (Cd) ................................................................................................................................. 28 Flow Rate Calibration (Fc) ............................................................................................................................. 28 Coolant Density (dS) ...................................................................................................................................... 28 Specific Heat (Sh) .......................................................................................................................................... 28 Current Control (CC)...................................................................................................................................... 28 Communications Baud Rate (PC).................................................................................................................. 29 Low Ambient Temperature Limit (LA) ............................................................................................................ 29 Password (Pd)................................................................................................................................................ 29 HGB Valve Delay (td)..................................................................................................................................... 29 Fuse Bits (Fb)................................................................................................................................................. 29

Enabling / Disabling the Local Lockout.............................................................................................................. 30 Display, Alarm and Error Messages.................................................................................................................. 31

Automatic Restart from Alarm Mode ................................................................................................................. 33 Routine Maintenance .......................................................................................................................................... 34

Recommended Routine Maintenance Schedule ............................................................................................... 34 Reservoir Coolant Level .................................................................................................................................... 34 Coolant Freeze Protection................................................................................................................................. 34 Inline Strainer..................................................................................................................................................... 34 Air Filters............................................................................................................................................................ 35

Troubleshooting .................................................................................................................................................. 36 Troubleshooting Chart ....................................................................................................................................... 36 Compressor Overload Fault (Ft20).................................................................................................................... 37

Low Pressure Sensor..................................................................................................................................... 37 High Pressure Sensor.................................................................................................................................... 37

Technical Information ......................................................................................................................................... 38

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Chiller Specifications ......................................................................................................................................... 38 Air-Cooled Chillers (DA500, DA750, DA1000) .............................................................................................. 38 Water-Cooled Chillers (DW500) .................................................................................................................... 38

Electrical Specifications..................................................................................................................................... 39 DA500 Chillers ............................................................................................................................................... 39 DW500 Chillers .............................................................................................................................................. 40 DA750 Chillers ............................................................................................................................................... 41 DA1000 Chillers ............................................................................................................................................. 41

Pump Performance............................................................................................................................................ 42 RS-232 Serial Communications (RS-485 Option) ............................................................................................. 43

Equipment Disposal (WEEE Directive) ............................................................................................................. 44 Service and Technical Support.......................................................................................................................... 44 PolyScience Chiller Fluids ................................................................................................................................. 45 Warranty............................................................................................................................................................... 45 Appendix .............................................................................................................................................................. 46

Flow Schematic – Air-Cooled Chillers ............................................................................................................... 46 Flow Schematic - Water-Cooled Chillers........................................................................................................... 47 Wiring Diagram - 5 HP and 7.5 HP Air-Cooled Chillers .................................................................................... 48 Wiring Diagram - 10 HP Air-Cooled Chillers...................................................................................................... 49 Wiring Diagram - 5 HP Water-Cooled Chillers .................................................................................................. 50 4-20 mA Set Point Control ................................................................................................................................. 51

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Introduction The PolyScience line of DuraChill Chillers provide cooling power for demanding applications and serve as an economical alternative to tap water cooling systems. All models feature a microprocessor-based controller, digital Temperature Display (°C or °F), one-touch set point display, and digital Pressure/Flow Rate Display (PSI, kPa, GPM, LPM) with push-button selection.

Standard and Optional Features DuraChill Chillers offer exceptional performance, reliability, and operational simplicity. Available in both air- and water-cooled models, these robust self-contained Chillers are engineered to provide accurate temperature control in a broad range of process cooling applications.

These powerful Chillers can be configured with a wide variety of standard and optional features, including:

Standard Features • Process temperature range: 32° to 86°F (0° to 30°C) • Ambient temperature range: 60° to 104°F (16° to 40°C) • Temperature stability: ±2.0°F (±1.1°C) • High efficiency vertical air exhaust • Accurate microprocessor control with digital LED readout • Pump protection by means of a Full Flow Bypass Valve • Copeland Scroll® compressor • Compressor protection through high and low refrigerant pressure cutouts • Process protection provided by over- and under-temperature alarms • RS-232 communications interface • Reservoir sight glass • Remote On / Off control (dry contact) • Dry contact status alarm output • Power phase monitor on 3-phase units • Heavy-duty locking casters for easy maneuverability • Stainless steel centrifugal pump (1 HP on 5 and 7.5 HP units; 2 HP on 10 HP units)

Optional Features • Other centrifugal and turbine pumps • RS-485 communications interface • Remote On / Off control (24 VDC) • Process shutoff valves • External bypass valve • Stainless steel reservoir • Heaters • Feet to replace casters • Reservoir level float switch • Side stream filter assemblies • External inlet / outlet filter assemblies • Deionized compatible process plumbing

A Configuration Data Sheet showing how your DuraChill Chiller is equipped is included with the manual if applicable (see inside front cover).

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General Safety Information

When installed, operated, and maintained according to the directions in this manual and common safety procedures, your DuraChill Chiller should provide safe and reliable temperature control. Please ensure that all individuals involved in the installation, operation, or maintenance of this Chiller read this manual thoroughly prior to working with the unit.

This symbol alerts you to wide range of potential dangers.

This symbol advises you of danger from electricity or electric shock.

This symbol indicates that a hot surface may be present.

This symbol marks information that is particularly important.

This symbol indicates alternating current.

This symbol indicates a protective conductor terminal. Only connect the unit to a power socket with earth (ground) contact (PE – protective earth). The power supply connector plug serves as a safe disconnecting device from the line and must always be easily accessible.

/ These symbols on the Power Switch / Disconnect indicate that they place the main power supply ON / OFF.

This symbol on the Power Button indicates that it places the unit in a standby mode. It DOES NOT fully disconnect the unit from the power supply.

Read all instructions pertaining to safety, set-up, and operation. Proper operation and maintenance is the user’s responsibility.

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Safety Recommendations It is the user’s responsibility to read and understand all instructions and safety precautions included in this manual prior to installing or operating this equipment. Contact our Customer Service Department with any questions regarding the operation of this Chiller or the information contained in this manual.

WARNING: All warning labels should be carefully observed. Never remove or obstruct a warning label.

WARNING: Installation, operation, or maintenance of this equipment should be performed in strict accordance with the instructions outlined in this manual. Failure to follow those instructions may increase the risk of personal injury, damage the equipment, and/or void the warranty.

WARNING: Be sure to remove power from the equipment, reclaim the refrigeration charge, and relieve any residual pressure before cutting into the refrigeration system.

WARNING: Do not attempt to operate leaking or damaged equipment.

WARNING: Service should only be performed by fully qualified personnel. Extreme caution is required as hazards are present when servicing this equipment.

WARNING: Do not attempt to override the power interlock switch or any other safety feature on this equipment.

WARNING: Disconnect electrical power before moving unit. Keep unit upright when moving. Always follow your company’s procedures and practices regarding safe lifting and relocation of heavy objects.

WARNING: Make sure the equipment’s main power switch is in the OFF position before connecting or disconnecting power. Follow all applicable electrical and safety codes and procedures when connecting power to the unit. Electrical connections should be made by an authorized electrical installer.

WARNING: This equipment must be properly filled with cooling fluid before use and properly drained before moving or service.

WARNING: Use only fluids that comply with safety, health, and equipment compatibility requirements. Read the safety data sheet for the fluid being used carefully before use.

CAUTION: Always operate this equipment within the stated design specifications.

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Regulatory Compliance and Testing CSA UL (5 HP 60Hz units)

CAN/CSA C22.2 No. 61010-1-04 — Safety Requirements for Electrical Equipment for Measurement, Control and Laboratory Use, Part I: General Requirements.

CAN/CSA C22.2 No. 61010-010-04 — Safety Requirements for Electrical Equipment for Measurement, Control and Laboratory Use - Part 2-010: Particular Requirements for Laboratory Equipment for the Heating of Materials.

UL Std No. 61010-1 (2nd edition) — Electrical Equipment for Laboratory Use, Part I: General Requirements.

CE (All 50Hz units)

EC Low Voltage Directive 2006/95/EC EC Electromagnetic Compatibility Directive 2004/108/EC IEC 61010-1-2001 IEC 61010-2-10 : 2005 IEC 61326-1:2005

Unpacking Your Chiller is shipped in a special container. Retain the container and all packing materials until the unit is completely assembled and working properly. Set up and run the unit immediately to confirm proper operation. If the unit is damaged or does not operate properly, contact the transportation company, file a damage claim and contact the company where your unit was purchased immediately.

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Controls and Components Your DuraChill Chiller consists of three basic sub-systems:

• Control • Fluid circulation • Cooling

This section describes these sub-systems in detail and includes information on the available options. Please note that your Chiller may or may not be equipped with all the components discussed.

Control System Control Panel — Temperature set point, temperature units, and other operating parameters are set via the Control Panel. Operating information is displayed on a local digital readout.

Power Switch / Disconnect — The main power switch is located on the front door of the Chiller. This switch also functions as a power disconnect when access to the unit’s components and terminal blocks is required; the access door cannot be opened until the Power Switch / Disconnect is placed in the OFF position.

NOTE: Loss of Power – In the event that power is lost while the Chiller is operating, the unit will automatically resume operation when the power is restored. If the unit was in Standby mode when power is lost, it will power up in Standby mode. The above is also true if power is removed via the Power Switch / Disconnect.

Temperature Probe — An internal RTD is used to measure fluid temperature downstream of the pump. Its reading is displayed on the Control Panel’s LED temperature display.

Flow Sensor — Monitors process fluid flow. If the flow rate is less than the user-settable alarm value, power to the pump, compressor, and fan is removed and an alarm message displayed on the Control Panel’s LED readout.

Flow Switch — Requires a minimum of ~4 gpm (15.1 lpm) to close. If the flow rate is too low, the switch will open and power to the pump, compressor, and fan removed; an alarm message will also be displayed on the Control Panel’s LED readout.

Fluid Pressure Sensor — Measures fluid pressure at the pump outlet. If the fluid pressure exceeds the user-settable alarm value, power to the pump, compressor, and fan is removed and an alarm message displayed on the Control Panel’s LED readout.

Refrigerant Pressure Switches — When activated, these switches remove power to the pump, compressor, and fan; an alarm message is also displayed on the Control Panel’s LED readout.

The Low Pressure Switch opens if the refrigerant pressure falls below 10 psi (0.7 bar) and closes if the pressure is above 30 psi (2.1 bar). The Low Pressure Switch will auto-reset.

The High Pressure Switch opens if the refrigerant pressure exceeds 630 psi (43.4 bar). The High Pressure Switch must be manually reset (see Troubleshooting, Compressor Overload Fault).

Pressure / Flow Rate Display

Units / Menu Select Button

Pressure / Flow Rate Unit

Temperature Display

Temperature Unit

Select / Set Knob

Power Button

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Fan Cycling Switch — This switch control fan operation. The fan turns ON when the discharge pressure of the refrigerant exceeds 400 psi (27.8 bar) and remains running until the pressure falls below 300 psi (20.7 bar).

NOTE: 10 HP Chillers have two fans. One fan turns ON with the compressor and runs continuously as long as the compressor is ON; operation of the second fan is based on refrigerant pressure as described above.

Reservoir Float Switch (Optional) — Measures liquid level in the Chiller’s reservoir. If the fluid level drops too low, power to the pump, compressor, and fan is removed and an alarm message displayed on the Control Panel’s LED readout.

Fluid Circulation System This sub-system governs fluid flow through the Chiller.

Evaporator — Serves as the heat exchanger between the refrigeration and fluid flow systems. Cools fluid before it returns to process.

Reservoir Tank — This polyethylene tank is used to maintain stable temperature control and an adequate reservoir of fluid for the system. It may be equipped with an optional float switch that monitors fluid level and activates an alarm. A stainless steel reservoir is available as an option.

Sight Glass or Level Indicator — This indicator serves as a convenient means of checking the liquid level within the Reservoir Tank. The sight glass is located on the rear panel.

Pump — Used to pump fluid from the Reservoir Tank to the process and back to the Chiller. A variety of pumps are available for operation at different pressures, flow rates, and distances from the Chiller to the process.

Internal Bypass — Allows the maximum operating pressure to be regulated and protects the Pump in the event that process piping becomes restricted or clogged. Diverts flow from the process line back to the Evaporator and Reservoir.

Y-Strainer — Located on the inlet to the Chiller. Incorporates a cleanable 20 mesh (841 micron) stainless steel screen to remove large particulate matter from the process fluid.

External Bypass / Shutoff Valves — Allows the unit to be operated independent of the process during the servicing of process equipment and/or process lines. Can also be used to fine-tune process pressure and flow rate.

Process Side-Stream Filter System (Optional) — Consists of a 50 micro filter and ball valve connected between the Chiller inlet and outlet. It is used to filter particulate matter from a portion of the process fluid flow.

Cooling System

NOTE: The Condenser on DuraChill Chillers is either air-cooled or water-cooled.

Common Cooling System Components

The following components are common to both air-cooled (DA models) and water-cooled (DW models) DuraChill Chillers:

Evaporator — Serves as the heat exchanger between the refrigeration and fluid flow systems. Removes heat from the process fluid before it is returned to the process equipment.

Compressor — The Chiller incorporates a 5 to 10 HP Copeland Scroll compressor. The Compressor is protected from overloads through high and low pressure cutouts.

Filter Dryer — Removes residual particulate matter and moisture from the refrigeration system. The Filter Dryer must be replaced whenever the sealed refrigeration lines are opened for service.

Sight Glass — Used to observe refrigerant fluid flow to the Evaporator.

Thermostatic Expansion Valve (TXV) — Controls refrigerant superheat at the outlet of the Evaporator to prevent liquid from returning to the Compressor.

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Hot Gas Bypass Solenoid Valve — Injects refrigerant vapor into the Evaporator to help maintain a constant temperature when the temperature of the process fluid falls below the temperature set point. Under low- and no-load conditions, temperature continues to fall until it reaches the “Lb” lower band and shuts the Compressor OFF.

Refrigerant Safety Relief Valve — This is an automatic safety used to vent refrigeration gas if it exceeds 650 psi (44.8 bar).

Air-Cooled Chillers (DA Models)

The following components are specific to air-cooled DuraChill Chillers:

Condenser — The Compressor pumps vapor into the Condenser at high pressure. As the surrounding air is cooler than the hot vapor, heat energy passes into the air from the condenser coils.

Condensing Fan — a 1 HP fan (two fans on 10 HP units) that draws air over the condenser coils to cool refrigerant gas. The standard fan cycles ON and OFF based on refrigerant pressure (ON at 400 psi / 27.6 bar; OFF at 300 psi / 20.7 bar). The second fan on 10 HP units runs whenever the Compressor is ON.

Water-Cooled Chillers (DW Models)

Brazed-Plate Heat Exchanger / Condenser — Serves as the heat exchanger between the refrigeration system and the facility water supplied by the customer. Removes heat from the refrigerant.

Condensing Water Regulating Valve — This valve regulates the facility water flow to maintain optimal discharge pressure (approximately 250 psi / 17.2 bar) for the heat exchange in the Condenser. It increases flow to decrease pressure and decreases flow to increase pressure.

Receiver — The main purpose of the Receiver is to temporarily store refrigerant (in its liquid state) that is not required when load conditions are low. The Receiver also provides a constant supply of liquid to the Thermostatic Expansion Valve (TXV).

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Component Identification Front – All Models

5 HP and 7.5 HP Chillers – Rear

Control Panel Power Switch / Disconnect

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10 HP Chillers – Rear

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Installation and Startup

WARNING: Be sure all power is OFF before proceeding.

Site Requirements Ambient Temperature and Relative Humidity

The Chiller is designed for indoor installation in ambient temperatures between 60° and 104°F (16° and 40°C); relative humidity should not exceed 80% (non-condensing).

Location

The Chiller should be installed on a strong, level surface capable of supporting 1050 lbs. / 476.3 kg (5 and 7.5 HP units) or 1500 lbs. / 680.1 kg (10 HP units).

It should be located as close to possible to the process requiring cooling and installed no closer than 4 feet (1.4 meters) to a heat-generating source, such as heating pipes, boilers, etc. If possible, the Chiller should be located near a suitable drain to prevent flooding in the event of leaks. Do not place it where corrosive fumes, excessive moisture, excessive dust, or high room temperatures are present.

For ease of positioning and maneuverability, the Chiller is supplied with casters. The front wheels can be locked to keep the Chiller in place while in use.

To help prevent voltage drops, position the Chiller as close as possible to the power distribution panel. Avoid voltage drops by using a properly grounded power source wired to meet electrical data plate requirements. The use of an extension cord is not recommended.

NOTE: The Chiller may be located at a level below that of the equipment being cooled. As long as the process remains closed, overflow will not occur when adding cooling fluid to the Chiller reservoir.

Clearance Adequate clearance should be allowed on the front, sides, and rear of the Chiller for access to connections and components. The front and rear vents of the Chiller must be a minimum of 24 inches (61 cm) away from walls or vertical surfaces so air flow is not restricted.

Overall Dimensions

Model Length Width Height

DA500 56 in. (142.2 cm) 34.5 in. (88 cm) 67 in. (170.2 cm)

DW500 56 in. (142.2 cm) 34.5 in. (88 cm) 32.1 in. (81.6 cm)

DA750 56 in. (142.2 cm) 34.5 in. (88 cm) 67 in. (170.2 cm)

DA1000 77 in. (195.6 cm) 34.5 in. (88 cm) 68.2 in. (173.2 cm)

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Electrical Power

WARNING: Make sure the main power switch is in the OFF position before connecting or disconnecting electrical power from the unit. Follow all applicable electrical and safety codes and procedures when connecting power to the unit. Electrical connections should be made by an authorized electrical installer.

WARNING:

Make certain that the electrical supply is the same voltage and frequency as your unit (see identification label).

Make sure electrical connections comply with all applicable electrical codes. Ground the Chiller in accordance with NEC Article 250. Operating voltage must be within 10% of the data plate rating. Phase imbalance must be below 5%.

WARNING: DO NOT apply power to the Chiller until the unit is ready for Startup

CAUTION: DO NOT apply power to the Chiller until the Reservoir has been filled. When Controller power is turned ON, the pump automatically begins pumping. If the Reservoir has not been filled, the pump could be damaged.

The Chiller is equipped with a phase monitor that prevents startup if phase sequence is incorrect. It will also turn the Chiller OFF in the event of a loss of one phase and/or prevent Chiller operation if there is a voltage mismatch between any two phases greater than 8%. Be sure to connect electrical lines in proper sequence, i.e.: L1, L2, and L3.

There is a junction box on the rear of the unit to which you can connect the electrical power supply conduit. Be sure to provide suitable conduit strain relief and grounding.

WARNING: DO NOT remove the ground wire while diagnosing any power supply problems.

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Signal Inputs/Outputs

Remote On / Off and Alarm Output

Remote On / Off

This allows the operator to turn the Chiller ON and OFF using a remote dry contact. The Chiller is ON when the contact is open; it is OFF when the contact is closed. A 10-ft (3 m) cord with 5-pin mating plug is provided.

Alarm Output

This allows the operator to connect a remote alarm device to the Chiller. The alarm output consists of normally open (NO) and normally closed (NC) contacts which are switched whenever an alarm, fault, or error condition is detected or when the Chiller is OFF. A 10-ft (3 m) cord with 5-pin mating plug is provided.

RS-232 Serial Communication (RS-485 Option)

This allows the operator to remotely control the Chiller and/or output temperature readings to an external recorder or other auxiliary device. A 9-pin D-connector is provided on the rear of the instrument enclosure for this connection.

The maximum communications distance for Chillers equipped with RS-232 is 50 feet (15 meters); the maximum distance for units equipped with the RS-485 option is 4000 feet (1200 meters).

See the Technical Information section for serial communications protocol and commands.

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External Piping

WARNING: All facility water connections must be made by a licensed plumber.

General Considerations

To maintain a safe workplace and avoid leaks, special care should be taken when choosing hoses and connectors for the Chiller. It is the user’s responsibility to ensure that the tubing and fittings connected to the Chiller are compatible with the fluid, temperature, and pressure being used.

• Pressure Ratings – Hoses should be able to withstand a minimum pressure of 250 psi (17.2 bar). • Flexible Tubing – Avoid tubing that will expand and increase fluid volume when operating at the desired

pressure. • Take care when selecting hoses and connections for the Chiller. All external piping, tubing, or hoses should

be run full size to limit the potential for external pressure drops. The use of quick-connect fittings is not recommended, as they can cause substantial pressure drops.

• Where applicable, always use a back-up wrench when making piping connections to the Chiller. • Hose Diameter – The fittings on the Chiller’s process fluid lines are female 1.5 in NPT. The facility water

fluid inlets and outlets on water-cooled models are female 0.75 inch NPT. • Facility Water (water-cooled models only) – Should be clean and well maintained. Ideally, the facility water

should be tested monthly to ensure a pH level between 7.2 and 7.8. Add algaecide if algae growth is present.

Process Fluid Connections

The Chiller has two internally threaded (1.5 inch ID NPT) fittings on the rear of the instrument housing for the process water connections.

Connect the Chiller’s inlet and outlet to the external apparatus with hoses or pipes. The direction of the flow through the system can be controlled by the way the connections are made. Fluid is drawn into the Chiller through the “Inlet” connection; fluid is pumped out of the Chiller through the “Outlet” connection.

Facility Water Connections

WARNING: The incoming cooling water pressure should be 20 psi / 1.4 bar minimum and 40 psi / 2.8 bar maximum.

Water-cooled Chillers have two internally threaded (0.75 inch ID NPT) on the rear of the instrument housing for the facility water connections. The cooling water supply should be connected to the facility water inlet on the Chiller. The facility water outlet on the Chiller should be connected to the appropriate return or drain, as required.

The cooling water supply may be from city tap water or a cooling tower. The incoming water pressure should be between 20 and 40 psi / 1.4 and 2.8 bar.

Reservoir Drain

A 0.75 inch NPT connection is provided at the bottom of the reservoir Sight Glass / Level Indicator for the reservoir’s gravity drain. It should be piped to a drain or receptacle positioned below the bottom of the reservoir. If a receptacle is used, be sure it is of sufficient volume to hold all the coolant in the reservoir, process, and process lines.

Reservoir Fill / Vent

A 0.75 inch female NPT connection is provided at the top of the Reservoir Sight Glass / Level Indicator.

If desired, you may add coolant to the Chiller through this connection to maintain an adequate fluid level. It is recommended that you fill the Reservoir initially via the fill port at the top of the Reservoir.

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If the Chiller is equipped with the heater option, a Reservoir vent should be installed. This vent relieves pressure within the Reservoir as coolant heats and expands.

It may be also necessary to vent and/or add a venting pipe to the Chiller to prevent siphoning and/or overflow due to the amount of fluid external to the Chiller’s reservoir and/or location of the process being cooled.

NOTE: If the amount of fluid present in the process piping when the Chiller is turned OFF exceeds the capacity of the Reservoir, it may be necessary to install a normally closed (NO) solenoid valve on the Chiller’s fluid inlet and a check valve on the Chiller’s fluid outlet to prevent backflow into the unit.

Internal Bypass

This allows the operator to adjust the maximum operating pressure to the process. Actual pressures vary with different pumps. It is recommended that pressures be set below 80 PSI (5.5 bar). The Internal Bypass is located on the left front side of the Chiller housing just above the pump.

Adjusting the Internal Bypass Pressure Setting

WARNING: Hazardous voltages are present.

The pressure setting on the Bypass is adjusted as follows:

1. Set the Pressure / Flow Rate Display to read in either PSI or kPa (see Normal Operation, Selecting the Pressure / Flow Rate Display and Units).

2. Using the valve handle, adjust the pressure until the reading on the Pressure / Flow Rate Display matches the desired maximum operating pressure. A clockwise rotation increases pressure; a counter-clockwise rotation decreases pressure.

3. Set the Pressure / Flow Rate Display to the preferred reading (GPM, LPM, PSI, kPa).

Internal Bypass Valve

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Process Coolant Suitable Fluids

WARNING: Use only fluids that comply with safety, health, and equipment compatibility requirements. Read the safety data sheet for the fluid being used carefully before use.

CAUTION: Do not fill the Reservoir with deionized water unless the Chiller is equipped with the DI water compatible plumbing option.

The Chiller is designed to accommodate a variety of coolant fluids (water, glycol mixtures, etc). For most applications above 60°F (16°C), distilled water is satisfactory. For operation below 60°F (16°C), the Chiller must be protected with an antifreeze solution. Laboratory grade ethylene glycol or propylene glycol and water in a 50/50 mixture is satisfactory from 5° to 60°F (-15° to +16°C). Select a fluid that is compatible with the Chiller’s wetted parts (brass, bronze, stainless steel, EPDM rubber, nylon, PVC).

CAUTION: Coolant freeze protection must be 25°F (14°C) below the lowest possible temperature. The lowest possible temperature is equal to the process temperature minus the Lower Band ‘Lb’ setting (see Normal Operation, Setting Operational Parameters / Limits, Lower Band).

WARNING: Do not use caustic, corrosive, or flammable fluids.

CAUTION: Operation below 15°C (59°F) requires antifreeze in the circulation fluid. DO NOT use automotive antifreeze as the additives may be harmful to the Chiller’s wetted parts.

DO NOT USE the following fluids: • Automotive antifreeze with additives**

• Hard tap water**

• Deionized water with a specific resistance > 1 meg ohm (except units with the DI water compatible plumbing

• Any flammable fluids

• Concentrations of acids or bases

• Solutions with halides: chlorides, fluorides, bromides, iodides or sulfur

• Bleach (Sodium Hypochlorite)

• Solutions with chromates or chromium salts

• Glycerin

• Syltherm fluids ** At temperatures above 40°C, additives or mineral deposits can adhere to the heater. If deposits are allowed to build up, the heater may overheat and fail. Higher temperatures and higher concentrations of additives can hasten deposit build up.

An algaecide may be added to the coolant fluid to prevent algae growth (see PolyScience Chiller Fluids).

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Startup

CAUTION: The first time the Chiller is operated it should run for 12 hours in the Standby mode to allow the compressor crankcase heater to boil off any refrigerant absorbed in the compressor oil.

CAUTION: DO NOT turn Controller power ON until the Reservoir has been filled. When Controller power is turned ON, the pump automatically begins pumping. If the Reservoir has not been filled, the pump may be damaged.

Facility Water Flow (water-cooled units only) 1. Open the valves to the facility water supply and return. 2. Check for leaks.

Filling the Reservoir 1. Remove the rear left panel of the Chiller housing. It is held in place with two captive screws.

2. Remove the reservoir cap located on the top of the Reservoir and, using a funnel, add fluid until it is approximately 2 inches (5.1 cm) below top of reservoir.

3. Once the fluid level is about 2 inches (5.1 cm) below the top of the reservoir, remove the funnel but do not replace the cap at this time.

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Starting Process Fluid Flow 1. Place the Power Switch / Disconnect in the ON position. The Control Panel displays will respond by

showing five decimal points (.....). This indicates that the Chiller is in the Standby mode and is ready for power up. If this is the first time the Chiller is being operated, allow it to run in the Standby mode for 12 hours (see Caution note above).

2. Press the Power Button on the Control Panel. The system startup sequence will begin and proceed as follows:

• The pump will turn on and fluid will begin circulating through the system.

CAUTION: On initial startup or after long periods of inactivity, run the Chiller for 10 seconds, turn power OFF, and restart five times to remove any air in the process lines.

• The set point temperature will appear briefly on the Temperature Display; after a few seconds, it will be replaced by the actual fluid temperature. The right decimal point will flash while the set point is being displayed.

• The system will go through a short initialization sequence. • Once initialization has been completed, the compressor will begin operating. When the pressure in the

discharge line reaches 400 psi (27.6 bar), the fan will turn ON. Water-cooled units: The coolant water regulating valve opens/closes to maintain the pressure in the discharge line at approximately 250 psi (17.2 bar).

• The Controller will display the actual process fluid temperature and the appropriate ‘degrees’ LED will be lit (C or F).

3. Check for leaks.

4. With the pump running, the reservoir’s fluid level will drop as the process and/or process cooling lines fill with fluid. Slowly add fluid to the reservoir until the liquid level remains stable. This means that the system is filled and any entrained air has been purged.

5. Replace the reservoir cap.

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Normal Operation

Power On When the Power Switch / Disconnect is placed in the ON position, the Controller goes into a “Standby” mode. Five decimal points (…..) will appear on the Controller’s displays.

CAUTION: DO NOT turn Controller power ON until the Reservoir has been filled. When Controller power is turned ON, the pump automatically begins pumping. If Reservoir has not been filled, the pump may be damaged.

Press the Controller’s Power Button. The system startup sequence will begin and proceed as follows:

• The pump will turn on and fluid will begin circulating through the system.

CAUTION: On initial startup or after long periods of inactivity, run the Chiller for 10 seconds, turn power OFF, and restart five times to remove any air in the process lines.

• The set point temperature will appear briefly on the Temperature Display; after a few seconds, it will be replaced by the actual fluid temperature. The right decimal point will flash while the set point is being displayed.

• The system will go through a short initialization sequence. • Once initialization has been completed, the compressor will begin operating. When the pressure in the

discharge line reaches 400 psi (27.6 bar), the fan will turn ON. Water-cooled units: The coolant water regulating valve opens/closes to maintain the pressure in the discharge line at approximately 250 psi (17.2 bar).

• The Controller will display the actual process fluid temperature and the appropriate ‘degrees’ LED will be lit (C or F).

Temperature Unit (°C or °F) Selection / Factory Default Reset The LEDs adjacent to the Temperature Display indicate the unit (°C or °F) used for Temperature Displays. To change from °C to °F or vice versa, proceed as follows:

To change to °F — Place the Power Switch / Disconnect in the OFF position. Press and hold the Units/Menu Select Button while returning the Power Switch / Disconnect to the ON position.

To change to °C — Place the Power Switch / Disconnect in the OFF position. Press and hold the Power Button on the front panel while returning the Power Switch / Disconnect to the ON position.

IMPORTANT: Temperature set point and many other user-settable operating parameters return to the original factory defaults when the temperature unit is changed. It is recommended that you record all user-settings before changing the temperature unit or performing a factory default reset so that these operating parameters can be restored easily to the desired values.

Pressure / Flow Rate Display

Units / Menu Select Button

Pressure / Flow Rate Unit

Temperature Display

Temperature Unit

Select / Set Knob

Power Button

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Adjusting the Set Point Temperature Press the Select/Set Knob on the front panel. The current set point temperature will be displayed and the decimal point at the bottom right of the display will flash, indicating the temperature can be changed.

Rotate the Select/Set Knob until the desired set point temperature is displayed. The setting is accepted after the Select/Set Knob is pressed a second time or automatically after a few seconds of inactivity.

Selecting the Pressure / Flow Rate Display and Units The Chiller can be set up to display either fluid pressure (in PSI or kPa) or flow rate in GPM or LPM. Pressing the Units/Menu Select Button briefly toggles through the available selections.

NOTE: The metric pressure reading displayed must be multiplied by 100 for the actual kPa value

NOTE: If there is no flow sensor fitted, the display will show “- -“ when GPM or LPM is selected.

NOTE: The flow rate readout is intended as a reference only. If accurate flow readings are required, an external flow meter is recommended.

Displaying Internal (P1) and External (P2) Probe Temperatures

The Units/Menu Select Button may also be used to quickly check the internal (P1) and external (P2) probe temperatures by pressing it once (for P1) or twice (for P2) after the LPM LED is lit. The probe ID will appear on the Pressure/Flow Rate Display and the probe temperature will appear on the Temperature Display. If an optional external probe is not installed, the P2 ID will appear but the Temperature Display will show all dashes.

Setting Operational Parameters / Limits

The Chiller’s various operational parameters, such as temperature, flow rate, and pressure alarm values, are all user-adjustable. They are accessed by pressing and holding the Units/Menu Button until HL appears on the Pressure/Flow Rate Display. Pressing and releasing the Units/Menu Button once HL appears allows you to scroll through the various parameters; rotating the Select/Set Knob allows you to change the displayed setting. You can accept the displayed value by either pressing the Select/Set Knob or allowing the display to timeout.

Operational parameter limit alarms will shut down the compressor, fan, pump and heaters. Some temperature values are only displayed and settable in ºC. A few parameters require a special keystroke sequence to access and change values.

NOTE: Some parameters listed may not be included in your version of software.

NOTE: The Ranges and Default Settings shown are for standard models. Ranges and Default Settings for your unit may differ depending on the options selected.

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Menu Item Description Choices / Ranges Default Setting

HL High Temperature Limit — Limits the maximum allowable set point temperature. Audio and visual alarm indicators are activated when the measured fluid temperature reaches the HL temperature setting.

NOTE: EHL will appear on the display if the High Limit value is set below the current set point.

5° to 131°F

(-15° to +55°C)

95°F (35°C)

LL Low Temperature Limit — Limits the minimum allowable set point temperature. Audio and visual alarm indicators are activated when the measured fluid temperature reaches the LL temperature setting.

NOTE: ELL will appear on the display if the Low Limit value is set above the current set point.

-4° to 80°F

(-20° to +27°C)

39°F (4°C)

HA High Ambient Temperature Limit — Maximum ambient temperature limit. Displayed and settable only in ºC. Should the ambient temperature rise above the HA value, the audio and visual alarms will activate and the compressor, heater, fan, and pump will turn OFF.

NOTE: The rated cooling capacity on air-cooled chillers is dependent on an ambient temperature below 104°F (40°C); performance will decrease as ambient temperature rises.

CAUTION: Continuous operation at ambient temperatures above 104°F (40ºC) is not recommended for any air-cooled or water-cooled chiller.

30° to 75ºC

Always displayed and set in °C

45 ºC

FP Maximum Fluid Pressure — Maximum allowable fluid pressure; settable in either PSI or kPa. Should the fluid pressure rise above the maximum fluid pressure value, the audio and visual alarms will activate and the compressor, heater, fan, and pump will turn OFF.

NOTE: The Chiller also incorporates a built-in pressure regulated bypass valve. It will maintain a maximum outlet pressure by diverting flow of the process fluid to the reservoir. The bypass valve may be adjusted by the customer.

CAUTION: Maximum operating pressure for the Chiller is 100 PSI (6.9 bar). Different pumps have different maximum operating pressures.

10 to 100 PSI

0.68 to 6.8 (x100) kPa

Reference:

0.68 = 68 kPa 6.8 = 680 kPa

10 psi = 68.9 kPa 100 psi = 689 kPa

100 PSI

6.8 x 100 kPa (680 kPa)

FL Minimum Flow Rate — Minimum allowable flow rate; settable in either GPM or LPM. Should the fluid flow rate drop below the minimum value, the audio and visual alarms will activate, and the compressor, heater, fan, and pump will turn OFF.

0 to 50 GPM

0 to 190 LPM

0 GPM

0 LPM

Lb Lower Band — This sets how many degrees the process temperature can fall below set point before the compressor will turn OFF. It is displayed and settable in °C only.

1.0° to 5.0°C


2.0°C

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Ub Upper Band — This sets how many degrees the process temperature can rise above set point before the compressor will turn ON. It is displayed and settable in °C only.

1.0° to 5.0°C


2.0°C

C1

C2

C3

Calibration Offset — Allows the Chiller’s displayed and control or externally sensed temperature to match an independent traceable standard. The Calibration Offset is displayed and settable in °C only.

C1 — Internal calibration offset

C2 — External calibration offset

C3 — External calibration offset

NOTE: A special keystroke sequence is required to adjust the Calibration Offset. See Calibration Offset.

±2.9°C


0.0°C

Cd Compressor Delay — Allows the operator to set the minimum amount of time allowed from when the Compressor turns OFF to when it turns back ON again.

NOTE: When the Compressor turns OFF because it has reached the Lb value, it will remain OFF until both the Ub (°C) value has been reached and the Cd (delay time) value has expired.

10 to 300 seconds 20 seconds

Fc Flow Rate Calibration — Allows adjustment of the displayed flow rate to match that of a known standard.

NOTE: During Flow Rate Calibration, the left hand LCD displays the desired flow rate in GPM. The right hand LCD displays the Gain value.

NOTE: A special keystroke sequence is required to adjust the Flow Rate Calibration. See Flow Rate Calibration.

Varies

Record current Gain value for

reference

dS Coolant Density — This value is set at the factory and should not be changed.

0.1 to 9.00 8.35 lb/gal

Sh Specific Heat — This value is set at the factory and should not be changed.

0.1 to 1.00 1.00 BTU/lb °F

CC Current Control (optional) – Allows setting of the set point temperature via a 4-20 mA analog signal.

YES = Enables current control NO = Disables current control

Yes or No No

PC Communications Baud Rate — Selects the baud rate for serial (RS-232/RS-485) communication.

24 (2400), 48 (4800), 96 (9600) or 192 (19200)

9600

LA Low Ambient Temperature Limit —Minimum ambient temperature limit. Displayed and settable only in ºC. Should the ambient temperature fall below the LA value, the audio and visual alarms will activate and the compressor, heater, fan, and pump will turn OFF.

1 to 7°C


2°C

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Pd Password — For factory use only. 0 to 999 0

td HGB Valve Delay — For factory use only. 0 to 999 2

Fuse Bits — The current Fuse Bits (Fb) setting appears after the td setting and can be viewed, but not changed. To change Fuse Bits (Fb) operational parameters, electrical power must be turned OFF and a special key stroke combination entered. See Fuse Bits (Fb) for detailed instructions.

Input Logic State h00 h01 h02 h04 h05 h06

Closed OFF ON OFF ON Remote On / Off

dry contact Open ON OFF

N/A

ON OFF

N/A

24 VDC OFF ON OFF ON Remote 24 VDC On / Off

0 VDC ON

N/A

OFF ON

N/A

OFF

Open OK OK OK Low Low Low

Fb

Water Level Float Switch

Closed Low Low Low OK OK OK

You can adjust the following settings for your particular application or simply accept the default values.

High Temperature Limit (HL)

This menu item serves two functions. First, it establishes the maximum allowable set point temperature and thus helps prevent an operator from inadvertently selecting a temperature set point above a pre-established value. Secondly, it serves as a high temperature alarm, automatically activating both audio and visual alarm indicators if the measured fluid temperature reaches the HL setting. This also causes the compressor, heater, fan, and pump to turn OFF.

To change the high limit value, rotate the Select/Set Knob until the desired value is displayed.

HL 95

Low Temperature Limit (LL)

This menu item also serves a dual function. First, it establishes the minimum allowable set point temperature and thus helps prevent an operator from inadvertently selecting a temperature set point below a pre-established value. Secondly, it serves as a low temperature alarm, automatically activating both audio and visual alarm indicators if the measured fluid temperature drops to the LL setting. This also causes the compressor, heater, fan, and pump to turn OFF.

To change the low limit value, rotate the Select/Set Knob until the desired value is displayed.

LL 39

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High Ambient Temperature Limit (HA)

NOTE: This value is always set in °C.

This menu item protects the Chiller from overheating due to a high ambient temperature. Should the ambient temperature rise above the limit value, the audio and visual alarms will activate and the compressor, heater, fan, and pump will turn OFF.

To change the high ambient temperature value, rotate the Select/Set Knob until the desired value is displayed on the Temperature Readout.

HA 45

Maximum Fluid Pressure (FP)

This is the maximum allowable fluid pressure and can be set in either PSI or kPa (the LED adjacent to the display indicates the active unit of measure). Should the fluid pressure rise above the maximum fluid pressure value, the audio and visual alarms will activate and the compressor, heater, fan, and pump will turn OFF.

To change the fluid pressure limit value, rotate the Select/Set Knob until the desired value is displayed on the Temperature Readout.

NOTE: When FP first appears, the PSI LED will be lit. To view the FP value in kPa, press the Units/Menu Button again. FP will remain on the display and the kPa LED will light up.

FP PSI

100

FP

kPa x 100

6.8

NOTE: The Chiller incorporates a built-in safety that automatically maintains fluid pressure below a valve-regulated pressure value. It maintains this maximum outlet pressure by diverting the flow of process fluid to the Reservoir (i.e., begin internally recirculating the fluid). A maximum pressure value is set at the factory, but is user-adjustable. See “Installation and Startup, External Piping, Internal Bypass” for information on changing the maximum outlet pressure value.

Minimum Flow Rate (FL)

This is the minimum allowable flow rate and can be set in either GPM or LPM (the LED adjacent to the display indicates the active unit of measure). Should the fluid flow rate drop below the minimum value, the audio and visual alarms will activate, and the compressor, heater, fan, and pump will turn OFF.

To change the minimum flow rate value, rotate the Select/Set Knob until the desired flow rate value is displayed on the Temperature Readout.

With FL set to “0”, the flow alarm is disabled, and the Chiller will continue to operate with the output flow blocked.

NOTE: When FL first appears, the GPM LED will be lit, indicating the FL value is GPM. To view the FL value in LPM, press the Units/Menu Button again. FL will remain on the display and the LPM LED will light up.

FL ● GPM 1.5

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FL ● LPM

06

Lower Band (Lb)

NOTE: This value is always displayed/set in °C.

This menu item allows you to set how many degrees the process temperature can fall below set point before the Compressor will turn OFF.

To change the lower band value, rotate the Select/Set Knob until the desired value is displayed.

Lb 2.0

Upper Band (Ub)

NOTE: This value is always displayed/set in °C.

This menu item allows you to set how many degrees the process temperature can rise above set point before the Compressor will turn ON.

To change the upper band value, rotate the Select/Set Knob until the desired value is displayed.

Ub 2.0

Calibration Offset (C1 / C2 / C3)

IMPORTANT: To prevent the operator from accidentally changing the calibration offset, a special keystroke sequence is required to access this function.

This menu item allows you to adjust the Chiller’s internal and/or external temperature reading to match that of a traceable standard. It allows you to offset the displayed temperature value by as much as ±2.9°C.

NOTE: Calibration offset values are always set and displayed in °C.

1. Press and hold the Units/Menu Button until HL appears on the display.

2. Press and release the Units/Menu Button until the operating parameter preceding the calibration value you wish to change appears on the display.

For C1 (Internal Calibration Offset), the preceding operating parameter is Ub For C2 (External Calibration Offset), the preceding operating parameter is C1 For C3 (External Calibration Offset), the preceding operating parameter is C2

3. Press and hold the Units/Menu Button.

4. While holding the Units/Menu Button, press and release the Select/Set Knob.

5. When CAL will appears on the Temperature Display, release the Unit/Menu Button. The current calibration offset value will appear on the Temperature Display and alternate with the fluid temperature reading (enabling you to simultaneously adjust the offset and see the effect on the temperature).

6. Rotate the Select/Set Knob until the desired calibration offset is displayed. Press the Select/Set Knob or simply allow the display to time out to accept the displayed value.

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C1 0.0

Compressor Delay (Cd)

This menu item allows you to adjust the minimum amount of time (in seconds) the Compressor should be OFF before it cycles back ON.

To change the compressor delay, rotate the Select/Set Knob until the desired value is displayed.

Flow Rate Calibration (Fc)

NOTE: Your Chiller’s flow rate is calibrated at the factory at the nominal flow value for the installed pump. Further adjustment is not necessary.

This menu item allows you to adjust the flow rate display to match that of a known standard.

1. Press and hold the Units/Menu Button until HL appears on the display. 2. Press and release the Units/Menu Button until Cd appears on the display. 3. Press and hold the Units/Menu Button. 4. While holding the Units/Menu Button, press and release the Select/Set Knob. 5. When CAL appears on the Temperature Readout, release the Units/Menu Button. 6. Rotate the Select/Set Knob until the desired offset is displayed. Press the Select/Set Knob or simply allow

the display to time out to accept the displayed value.

Coolant Density (dS)

This menu item is for factory use only and should not be changed.

Specific Heat (Sh)

This menu item is for factory use only and should not be changed.

Current Control (CC)

This optional menu item allows you to adjust the temperature set point using a 4-20 mA analog signal. To change the displayed setting, rotate the Select/Set Knob until the desired selection is displayed (YES = enabled; NO = disabled).

Cd 20

Fc 0.0

dS 8.35

Sh 1.00

CC NO

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Communications Baud Rate (PC)

This menu item allows you to establish the baud rate for serial communication. Allowable settings are 0 (no serial communication), 24 (2400 baud), 48 (4800 baud), 96 (9600 baud), 192 (19200 baud).

To change the displayed setting, rotate the Select/Set Knob until the desired baud rate is displayed.

Press the Select/Set Knob or allow the display to time out to accept the displayed value.

Low Ambient Temperature Limit (LA)

NOTE: This value is always set in °C.

This menu item sets the lowest allowable ambient temperature at which the Chiller should operate. Should the ambient temperature fall below the limit value, the audio and visual alarms will activate and the compressor, heater, fan, and pump will turn OFF.

To change the low ambient temperature value, rotate the Select/Set Knob until the desired value is displayed on the Temperature Readout.

LA 2

Password (Pd)

This menu item is for factory use only and is not operator adjustable.

HGB Valve Delay (td)

This menu item is for factory use only and is not operator adjustable.

Fuse Bits (Fb)

This menu item allows you to select the logic settings for remote control and the water level float switch. To set fuse bits, proceed as follows:

1. Place the Power Switch / Disconnect in the OFF position. 2. Press and hold the Select/Set Knob and Power Button simultaneously. 3. While holding the Select/Set Knob and Power Button, place the Power Switch / Disconnect in the ON

position. 4. Fb will appear on the Pressure/Flow Rate Display; h followed by two digits will appear on the Temperature

Display. 5. Rotate the Select/Set Knob to the desired setting (h00, h01, h02, h04, h05, or h06). 6. Press and release the Select/Set Knob or simply allow the display to time out to accept the displayed

setting.

PC 96

Pd 0

td 2

Fb h00

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Enabling / Disabling the Local Lockout This feature is used to prevent unauthorized or accidental changes to set point and other operational values. When enabled, the values for set point and operational parameters can be displayed, but not changed:

To enable the local lockout, press and hold the Select/Set Knob until LLO is displayed (approximately 5 seconds). Once enabled, LLO will appear momentarily when the Select/Set Knob is pressed to display the set point.

To disable the local lockout, press and hold the Select/Set Knob until CAn appears momentarily as local lockout status changes from enabled (LLO) to disabled (approximately 5 seconds).

IMPORTANT: The Local Lockout feature does not prevent set point changes entered via the RS-232 interface.

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Display, Alarm and Error Messages When an alarm or error condition is detected, Ft appears on the Pressure/Flow Rate Display and a corresponding code flashes on the Temperature Display. Operational limit parameter alarms will shut down the compressor, fan, pump, and heaters. Alphabetical codes will also appear on the Temperature Display. An audio alarm will also sound.

After taking corrective action, restart the Chiller to clear the fault or error.

Code Description Action Required Default

02 Low limit temperature alarm Alarm – Process fluid temperature has dropped below the low limit temperature setting. Increase heat load or decrease LL setting.

39°F (4°C)

03 High limit temperature alarm Alarm – Process fluid temperature has reached the high limit temperature setting. Decrease heat load or increase HL setting.

95°F (35°C)

04 Over-temperature alarm (select models only)

Alarm – Process fluid temperature is above the factory set high temperature cutout. Air-cooled units: Cutout will reset automatically after the temperature of the fluid is lowered. Water-cooled units: Reset cutout manually by pressing red button on rear of unit after the temperature of the fluid is lowered.

Units without heater option

“OPT” jumpered on

PCB

05 Low liquid level alarm (units with Liquid Level Float Switch option only)

Delayed Alarm – Activated when the liquid level in the Reservoir falls below an acceptable level for 30 seconds. Wired in series with mechanical flow switch; see 07 low flow alarm.

See Fuse Bit settings

07 Low flow alarm

Alarm – Flow rate has dropped below minimum flow rate setting. Correct low flow condition or decrease FL setting. Secondary: Mechanical flow switch closes with flow (~4 gpm / 15 lpm minimum). If installed in combination with optional liquid level float switch, they are wired in series and both must be closed. If either is open due to low flow or low liquid level, this alarm or EFL will be activated. See EFL.

~4 gpm (15 lpm) minimum

required for flow switch

08 High pressure alarm

Delayed Alarm – Activated when the fluid outlet pressure has exceeded the high pressure limit setting for 30 seconds. Decrease outlet pressure or increase FP setting.

100 psi (689 kPa)

09 Internal software fault

10 Triac fault

Fault – Default unit to °C or °F. If fault persists, replace Control PCB. Note: Some parameters will reset to default values; this could activate another fault code. Review and return all parameters to user settings.

N/A

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11 Internal RTD probe fault

12 External RTD probe fault

Fault – RTD sensor failure. Check for open or shorted sensor (reference resistance value: 100 ohms @ 0°C / 138.5 ohms @ 100°C. If probe tests good, replace Control PCB.

N/A

13 Communications fault

14 ADC fault, internal probe

15 ADC fault, external probe

Fault – Default unit to °C or °F. If fault persists, replace Control PCB. Note: Some parameters will reset to default values; this could activate another fault code. Review and return all parameters to user settings.

N/A

16 High ambient temperature alarm, front panel (select models only)

17 High ambient temperature alarm, rear panel (select models only)

Alarm – Maximum ambient temperature limit has been exceeded. Note: The cooling capacity of air-cooled units is dependent on an ambient temperature below 104°F (40°C); performance will decrease as ambient temperature increases. Continuous operation at ambient temperatures above 104°f (40°C) is not recommended for any air-cooled or water-cooled Chiller.

45°C

18 Ambient temperature probe fault (P3) (select models only)

Fault – RTD sensor failure. Check for open or shorted sensor (reference resistance value: 100 ohms @ 0°C / 138.5 ohms @ 100°C. If probe tests good, replace Control PCB.

N/A

19 Pump overload (DAP1) fault Pump – Check continuity across DAP1 on PCB through NO contacts on overload relay; reset overload relay; check pump fuses.

N/A

20 Compressor overload (DAF2) Compressor pressure sensors. See Troubleshooting. N/A

21 Fan overload (DAF1) fault

Fan(s) – Check continuity across DAF1 on PCB through NO contacts on overload relay; check fan(s) fuses. Note: On 10 HP Chillers, both overload relays NO contacts are wired in series with DAF1.

N/A

22 Pump 2 overload (DAP2) fault (select models only)

Pump 2 option only – Check continuity through NO contacts on overload relay; reset overload relay; check pump fuses.

DAP2 jumpered on

PCB

EFL Low liquid level or low fluid flow

Warning / Alarm – Fluid level or float switch is open. Alarm will sound once every 8 seconds for 5 occurrences. If problem has not been corrected after 40 seconds, Fault 05 occurs.

N/A

EHA High ambient temperature alarm

Alarm – The ambient temperature (as measured on the Control PCB) is higher than the high ambient temperature setting. If ambient temperature stays over 5°C above the HA setting, Fault 16 or 17 is activated. Lower ambient temperature or increase the HA setting.

45°C

EHL High limit temperature alarm

Alarm – The temperature set point is higher than the high limit temperature setting. The display alternates between EHL and the fluid temperature. The unit continues normal operation. If the fluid temperature rises above the HL setting, Fault 03 is activated. Decrease heat load or increase the HL setting.

95°F (35°C)

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ELL Low limit temperature alarm

Alarm – The temperature set point is lower than the low limit temperature setting. The display alternates between ELL and the fluid temperature. The unit continues normal operation. If the fluid temperature drops below the LL setting, Fault 02 is activated. Increase heat load or decrease the LL setting.

39°F (4°C)

LO H2O No fluid flow or pressure

Warning – LO is displayed alternately with H2O and the fluid temperature. Indicates that the fluid pressure exceeds the high pressure limit or the fluid flow is less than the low flow limit. If either error persists, Fault 07 or 08 will be activated.

N/A

ECC Error current control Alarm – The current input is outside 4-20 mA. Pump, compressor, and fan turn OFF. Send in-range 4-20 mA input to restart Chiller.

N/A

The following Codes indicate display control status.

Code Description Action Required

LLO Local lockout Normal – Indicates that the Local Lockout feature is enabled. Appears momentarily when the Select/Set Knob is pressed to view/change set point value. See Enabling/Disabling the Local Lockout.

CAn Cancel local lockout Normal – Indicates that the Local Lockout feature has been disabled. Appears momentarily when Local Lockout status is changed from enabled (LLO) to disabled. See Enabling/Disabling the Local Lockout.

EC External remote control active Normal – Chiller is in Standby mode until remotely activated (optional)

Automatic Restart from Alarm Mode The Chiller is equipped with an automatic restart feature to avoid false or nuisance alarms due to temporary flow obstructions, temperature swings, or electrical line noise. If any alarm condition is detected, the Chiller will turn OFF, wait 30 seconds, and turn back ON automatically. If the alarm condition persists after three restart attempts are made, then an alarm will sound and the Chiller will remain OFF until the problem is corrected.

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Routine Maintenance

Recommended Routine Maintenance Schedule

Routine Maintenance Procedure Frequency1

Check reservoir coolant level Monthly

Check coolant freeze protection Monthly

Inspect and clean inline strainer Weekly for first month of operation; every 3 months thereafter.

Inspect and clean air filters Weekly for first month of operation; every 3 months thereafter.

1. Minimum maintenance frequency. Your plant conditions may require more frequent inspection and cleaning.

Reservoir Coolant Level The coolant level in the Reservoir should be checked on a monthly basis and replenished as required. A proper fill level is approximately 2 inches (5.1 cm) below the top of the Reservoir. If fluid replacement is required, slowly add coolant until the proper fill level is achieved. You may add coolant either directly to the Reservoir or through the top of the Liquid Level Sight Glass on the rear of the unit.

Coolant Freeze Protection

CAUTION: Coolant freeze protection must be 25°F (14°C) below the lowest possible temperature. The lowest possible temperature is equal to the process temperature minus the Lower Band (Lb) setting. See Normal Operation, Setting Operational Parameters / Limits.

If your Chiller is operating below 59°F (15°C), it must be protected with an antifreeze solution. The coolant should be checked periodically for proper freeze protection.

Inline Strainer The Chiller’s inline strainer should be inspected and cleaned weekly for the first month of operation. Once you are certain that all debris that has been generated or dislodged has been removed from the process coolant, strainer inspection and cleaning should be performed every three months or as required, whichever is more frequent.

1. Place the Power Switch / Disconnect in the OFF position.

2. Remove the Chiller’s left side rear panel. The inline strainer is located just above the Reservoir at the inlet to the Chiller.

3. Using an adjustable wrench or the proper size hex head socket, loosen and remove the inline strainer cap and screen.

NOTE: There will be a small amount of residual coolant within the housing of the inline strainer which will drain out when the cap is removed.

4. Clean the screen. Either water or high pressure air can be used to remove accumulated debris.

5. Replace screen and drain cap and tighten.

6. Place Power Switch / Disconnect in the ON position.

7. Check for leaks before replacing left rear side panel.

110-279 35

Air Filters Chillers incorporate two or more high-efficiency, removable air filters. These should be inspected weekly during the first month of operation to determine how frequently cleaning is required. Units located in dusty or oily environments will require more frequent air filter cleaning.

CAUTION: DO NOT allow the air filters to become caked with dust or coated with an oily film. This significantly reduces air flow and will decrease cooling efficiency. It can also lead to filter breakthrough, allowing dust and oil to get into and on the fins and coils of the condenser.

The Chiller’s air filters are removed and cleaned as follows:

1. Grasp the strap at the bottom center of the air filter and gently lift up and away from the Chiller housing.

2. Direct water or a high pressure air stream through the back of the filter (downstream side) opposite the air flow arrow. If using water, allow the filter to dry before reinstalling.

3. Position the top edge in the upper channel of the Chiller housing, with the air flow arrow pointing toward the inside of the Chiller housing.

4. Gently lift on the bottom strap and push the bottom edge of the filter toward the housing until the filter is securely in place.

110-279 36

Troubleshooting

NOTE: Many problems can be resolved by restoring the factory defaults. If this solves the problem, be careful when restoring your operational settings in order not to repeat the problem. To restore the factory default settings: 1. Place the Power Switch / Disconnect in the OFF position. 2. Press and hold the Units/Menu Button (for °F) or the Power Button (for °C) while returning the

Power Switch / Disconnect to the ON position.

WARNING: Service should only be performed by qualified personnel. Extreme caution is required as hazards are present when servicing this equipment.

WARNING: When electrical power is ON, dangerous voltages exist within chassis components. Use extreme care when measuring voltages on live circuits.

Troubleshooting Chart

Problem Possible Causes Corrective Action Unit does not run (digital displays blank)

No power to unit Check that the electrical wiring is secure and connected to an operating electrical source. Check that Power Switch / Disconnect is in the ON position. Check the phase monitor indicator light for correct phase wiring.

Unit does not run (three decimal points appear on Temperature Display, two decimal points on Pressure/Flow Rate Display)

Unit in Standby mode Press Power Button on front panel.

No fluid circulation Insufficient fluid in reservoir Blockage in circulating system Pump is not operating

Add fluid to reservoir. Remove blockage. Replace pump.

Insufficient circulation Fluid viscosity too high External tubing diameter too small Restrictions in fluid lines Low or high line voltage

Replace with lower viscosity fluid. Replace with larger diameter tubing. Check and correct as required. Check and correct as required.

Unit does not cool or cooling is insufficient

Dust build up on air filter or condenser Blocked air ventilation screens Facility water too warm Excessive heat load Ambient air temperature too high Low or high line voltage

Clean air filter and/or condenser as required. Remove blockages as required. Check and correct as required. Check that heat load does not exceed capacity of Chiller; correct as required. Decrease ambient air temperature. Check and correct as required.

Fault code 20 on display Refrigerant pressure too high Refrigerant pressure too low Faulty refrigerant pressure sensor

See Compressor Overload Fault, below.

110-279 37

Compressor Overload Fault (Ft 20) The Chiller has both low and high refrigerant pressure sensors. They are wired in series and connect to DAF2 on the Control PCB. If either sensor opens, the Ft 20 alarm is activated. To troubleshoot, measure the continuity across each senor.

Low Pressure Sensor

The low pressure sensor opens if the suction pressure drops below 15 psi (1 bar) and automatically closes when the suction pressure rises above 30 psi (2.1) bar. If a continuity check of this sensor shows that it is open, it is probably due to a loss of refrigerant, although a faulty sensor cannot be ruled out. Contact your local HVAC technician to check the refrigeration system.

High Pressure Sensor

The high pressure sensor opens if the discharge pressure exceeds 630 psi (43.4 bar). If a continuity check shows that this sensor is open, it may be due to high ambient temperature, dirty air filters, or large heat loads. A faulty sensor cannot be ruled out.

Once the high pressure sensor opens, it must be manually reset as follows:

WARNING: Compressor and copper tubing may be very hot.

1. Remove the front right side panel of the Chiller housing.

2. Locate the blue sensor with red reset button on the compressor discharge line.

3. Depress the red reset button.

4. Replace front right side panel.

If high ambient temperature, dirty air filters, or large heat loads have been ruled out as reasons for an open high pressure sensor and the sensor remains open or continues to open, contact your local HVAC technician to check the refrigeration system.

110-279 38

Technical Information Chiller Specifications Air-Cooled Chillers (DA500, DA750, DA1000)

Model DA500 DA750 DA1000

Process temperature range 32° to 86°F (0° to 30°C)

Temperature stability ±2.0°F (±1.11°C)

Ambient operating temperature 60° to 104°F (16° to 40°C)

Copeland Scroll compressor 5 HP 7.5 HP 10 HP

Refrigerant charge (R-410A) 8 lbs. (3.6 kg) 12 lbs. (5.4 kg) 16 lbs. (7.3 kg)

Cooling capacity1 60 Hz models

16,384 watts 55,869 BTU

22,361 watts 76,251 BTU

33,436 watts 114,016 BTU

Cooling capacity1 50 Hz models

14,418 watts 50,515 BTU

19,678 watts 67,102 BTU

29,424 watts 100,336 BTU

Nominal evaporator flow2 11.7 USGPM (44.3 lpm)

15.7 USGPM (59.4 lpm)

23.8 USGPM (90.1 lpm)

Fan 1 HP 1 HP 1 HP x 2

Condenser discharge air flow 6000 CFM 6000 CFM 6000 CFM

Reservoir tank capacity 16 gallons (60.5 liters) 16 gallons (60.5 liters) 45 gallons (170 liters)

Process water connections 1.5 inch FPT

Dimensions (L x W x H) 56 x 34.5 x 67 in. 142.2 x 88 x 170.2 cm

56 x 34.5 x 67 in. 142.2 x 88 x 170.2 cm

77 x 34.5 x 68.2 in. 195.6 x 88 x 173.2 cm

1. Capacity based on 68°F (20°C) entering air and 68°F (20°C) leaving water. 2. Chiller flow rate based on 2.4 USGPM/ton (0.54 m3/hr/ton)

Water-Cooled Chiller (DW500)

Model DW500

Process temperature range 32° to 86°F (0° to 30°C)

Temperature stability ±2.0°F (±1.11°C)

Ambient operating temperature 60° to 104°F (16° to 40°C)

Copeland Scroll compressor 5 HP

Refrigerant charge (R-410A) 8 lbs. (3.6 kg)

Cooling capacity 60 Hz models

17,825 watts 60,840 BTU

Cooling capacity 50 Hz models

14,850 watts 50,715 BTU

Nominal evaporator flow1 12.7 USGPM (48.1 lpm)

Condenser water flow2 15.4 USGPM (58.1 lpm)

Reservoir tank capacity 16 gallons (60.5 liters)

Process water connections 1.5 inch FPT

Facility water connections 0.75 inch FPT

Dimensions (L x W x H) 56 x 34.5 x 32.1 inches / 142.3 x 88 x 81.6 cm 1. Chiller flow rate based on 2.4 USGPM/ton (0.54 m3/hr/ton) 2. Tower flow rate based on 85°F (29°C) entering water and 95°F (35°C) leaving water.

Specifications subject to change without notice.

110-279 39

Electrical Specifications DA500 Chillers

Max. Operating Current / Fuse –

Circuit Breaker Size with no heaters


Circuit Breaker Size with 3000 Watt Heater

Option



Option



Option Model Voltage / Phase / Hertz

Max. Amps

Fuse – CB Size

Max. Amps

Fuse – CB Size

Max. Amps

Fuse – CB Size

Max. Amps

Fuse – CB Size

DA504F 208-230V / 3 / 50-60 29.4 45 36.6 55 47.4 70 51.1 75

DA504G 208-230V / 3 / 50-60 32.6 50 39.8 60 50.6 75 54.3 80

DA504C3 208-230V / 3 / 50-60 35.1 55 42.3 65 53.1 80 56.8 80

DA504C5 208-230V / 3 / 50-60 39.7 60 46.9 75 57.7 85 61.4 85

DA504D1/S1 208-230V / 3 / 50-60 31.4 50 38.6 60 49.4 75 53.1 80

DA504D2/S2 208-230V / 3 / 50-60 35 55 42.2 65 53 80 56.7 80

DA504D3/S3 208-230V / 3 / 50-60 39 60 46.2 70 57 85 60.7 85

DA504D6/S6 208-230V / 3 / 50-60 32.6 50 39.8 60 50.6 75 54.3 80

DA506F 380V / 3 / 50 15.2 25 18.8 30 26 40

DA506G 380V / 3 / 50 16.7 25 20.3 30 27.5 40

DA506C3 380V / 3 / 50 17.2 25 20.8 30 28 40

DA506C5 380V / 3 / 50 18.3 30 21.9 35 29.1 45

DA506D1/S1 380V / 3 / 50 16.2 25 19.8 30 27 40

DA506D2/S2 380V / 3 / 50 18.1 30 21.7 35 28.9 45

DA506D3/S3 380V / 3 / 50 19.6 30 23.2 35 30.4 45

DA506D6/S6 380V / 3 / 50 16.8 25 20.4 30 27.6 40

DA508F 460V / 3/ 60 15.4 25 19 30 26.2 40

DA508G 460V / 3/ 60 16.9 25 20.5 30 27.7 40

DA508C3 460V / 3/ 60 18 30 21.6 35 28.8 45

DA508C5 460V / 3/ 60 20 30 23.6 35 30.8 45

DA508D1/S1 460V / 3/ 60 16.2 25 19.8 30 27 40

DA508D2/S2 460V / 3/ 60 17.5 25 21.1 35 28.3 40

DA508D3/S3 460V / 3/ 60 20.2 30 23.8 35 31 45

DA508D6/S6 460V / 3/ 60 16.4 25 20 30

NA

27.2 40

For 575 Volt units consult the factory

110-279 40

DW500 Chillers





Option



Option




Max. Amps

Fuse – CB Size

Max. Amps

Fuse – CB Size

Max. Amps

Fuse – CB Size

Max. Amps

Fuse – CB Size

DW504F 208-230V / 3 / 50-60 25.4 40 32.6 50 43.4 70 47.1 70

DW504G 208-230V / 3 / 50-60 28.6 45 35.8 55 46.6 70 50.3 75

DW504C3 208-230V / 3 / 50-60 31.1 50 38.3 60 49.1 75 52.8 80

DW504C5 208-230V / 3 / 50-60 35.7 55 42.9 65 53.7 80 57.4 80

DW504D1/S1 208-230V / 3 / 50-60 27.4 45 34.6 55 45.4 70 49.1 75

DW504D2/S2 208-230V / 3 / 50-60 31 50 38.2 60 49 75 52.7 80

DW504D3/S3 208-230V / 3 / 50-60 35 55 42.2 65 53 80 56.7 80

DW504D6/S6 208-230V / 3 / 50-60 28.6 45 35.8 55 46.6 70 50.3 75

DW506F 380V / 3 / 50 13.2 20 16.8 25 24 35

DW506G 380V / 3 / 50 14.7 25 18.3 30 25.5 40

DW506C3 380V / 3 / 50 15.2 25 18.8 30 26 40

DW506C5 380V / 3 / 50 16.3 25 19.9 30 27.1 40

DW506D1/S1 380V / 3 / 50 14.2 20 17.8 30 25 40

DW506D2/S2 380V / 3 / 50 16.1 25 19.7 30 26.9 40

DW506D3/S3 380V / 3 / 50 17.6 25 21.2 35 28.4 40

DW506D6/S6 380V / 3 / 50 14.8 25 18.4 30 25.6 40

DW508F 460V / 3/ 60 13.3 20 16.9 25 24.1 35

DW508G 460V / 3/ 60 14.8 25 18.4 30 25.6 40

DW508C3 460V / 3/ 60 15.9 25 19.5 30 26.7 40

DW508C5 460V / 3/ 60 17.9 30 21.5 35 28.7 40

DW508D1/S1 460V / 3/ 60 14.1 20 17.7 30 24.9 40

DW508D2/S2 460V / 3/ 60 15.4 25 19 30 26.2 40

DW508D3/S3 460V / 3/ 60 18.1 30 21.7 35 28.9 40

DW508D6/S6 460V / 3/ 60 14.3 20 17.9 30

NA

25.1 40


110-279 41

DA750 Chillers





Option




Max. Amps

Fuse – CB Size

Max. Amps

Fuse – CB Size

Max. Amps

Fuse – CB Size

DA756F 380V / 3 / 50 20.7 30 24.3 40 31.5 50

DA756G 380V / 3 / 50 22.2 35 25.8 40 33 50

DA756C3 380V / 3 / 50 22.7 35 26.3 40 33.5 50

DA756C5 380V / 3 / 50 23.8 35 27.4 40 34.6 55

DA756D1/S1 380V / 3 / 50 21.7 35 25.3 40 32.5 50

DA756D2/S2 380V / 3 / 50 23.6 35 27.2 40 34.4 55

DA756D3/S3 380V / 3 / 50 25.1 40 28.7 45 35.9 55

DA756D6/S6 380V / 3 / 50 22.3 35 25.9 40 33.1 50

DA758F 460V / 3/ 60 20.9 30 24.5 40 31.7 50

DA758G 460V / 3/ 60 22.4 35 26 40 33.2 50

DA758C3 460V / 3/ 60 23.5 35 27.1 40 34.3 55

DA758C5 460V / 3/ 60 25.5 40 29.1 45 36.3 55

DA758D1/S1 460V / 3/ 60 21.7 35 25.3 40 32.5 50

DA758D2/S2 460V / 3/ 60 23 35 26.6 40 33.8 50

DA758D3/S3 460V / 3/ 60 25.7 40 29.3 45 36.5 55

DA758D6/S6 460V / 3/ 60 21.9 35 25.5 40 32.7 50


DA1000 Chillers





Option




Max. Amps

Fuse – CB Size

Max. Amps

Fuse – CB Size

Max. Amps

Fuse – CB Size

DA1006F 380V / 3 / 50 24.6 40 28.2 45 35.4 55

DA1006G 380V / 3 / 50 26.1 40 29.7 45 36.9 55

DA1006C3 380V / 3 / 50 26.6 40 30.2 45 37.4 55

DA1006C5 380V / 3 / 50 27.7 45 31.3 45 38.5 60

DA1006D1/S1 380V / 3 / 50 25.6 40 29.2 45 36.4 55

DA1006D2/S2 380V / 3 / 50 27.5 45 31.1 50 38.3 60

DA1006D3/S3 380V / 3 / 50 29 45 32.6 50 39.8 60

DA1006D6/S6 380V / 3 / 50 26.2 40 29.8 45 37 55

DA1008F 460V / 3/ 60 24.9 40 28.5 45 35.7 55

DA1008G 460V / 3/ 60 26.4 40 30 45 37.2 55

DA1008C3 460V / 3/ 60 27.5 45 31.1 45 38.3 60

DA1008C5 460V / 3/ 60 29.5 45 33.1 50 40.3 60

DA1008D1/S1 460V / 3/ 60 25.7 40 29.3 45 36.5 55

DA1008D2/S2 460V / 3/ 60 27 40 30.6 45 37.8 55

DA1008D3/S3 460V / 3/ 60 29.7 45 33.3 50 40.5 60

DA1008D6/S6 460V / 3/ 60 25.9 40 29.5 45 36.7 55


110-279 42

Pump Performance

Stainless Steel Centrifugal Nom. 240/460V

3 phase Bronze Turbine Nom. 240/460V

3 phase

1 HP centrifugal1 F 215-733 1.5 HP turbine D1 215-483

2 HP centrifugal2 G 215-678 2 HP turbine D6 215-354

3 HP centrifugal C3 215-738 3 HP turbine D2 215-484

5 HP centrifugal C5 215-780 5 HP turbine D3 215-485

Stainless Steel Turbine Nom. 240/460V

3 phase

1.5 HP turbine S1 215-536

2 HP turbine S6 215-479

1. Standard on 5 HP Chillers 2. Standard on 7.5 and 10 HP Chillers

3 HP turbine S2 215-537

110-279 43

RS-232 Serial Communications (RS-485 Option) Serial Connector — A 9-pin D-connector (optional) is provided on the back panel of the Chiller for RS-232 / RS-485 data communication. A serial cable that uses only the following pins should be used to connect the Chiller to the computer:

RS-232 RS-485

Pin # 2 data read (data from computer) Pin # 3 DAT (+) on “B”

Pin # 3 data transmit (data to computer) Pin # 5 signal ground

Pin # 5 signal ground Pin # 9 DAT (-) on “A” RS-232 / RS-485 Protocol — The controller uses the following RS-232 / RS-485 protocol:

Data bits — 8 Parity — none Stop bits — 1 Flow control — none Baud rate — selectable (Chiller and PC baud rates must match).

Communications Commands — Commands must be entered in the exact format shown. Do not send a [LF] (line feed) after the [CR] (carriage return). Be sure to follow character case exactly. A question mark (?) indicates that the Chiller could not execute the command (either because it was in an improper format or the values were outside the allowable range). A response followed by an exclamation point (!) indicates that a command was executed correctly. A response must be received from the Chiller before another command can be sent. All responses are terminated with a single [CR].

Command Description Command Format Values Return Message

Set command echo SEi[CR] Echo: i = 1 No Echo: i = 0 ![CR]

Set On / Off SOi[CR] On: i = 1 Off: i = 0 ![CR]

Turn chiller On / Off SOi[CR] On: i = 1 Off: i = 0 ![CR]

Set set point SSxxx[CR] x = ASCII digit 41° to 95°F (5° to 35°C) ![CR]

Read set point temperature RS[CR] ----- ![CR]

Read temperature RT[CR] ----- ![CR]

Read temperature units RU[CR] ----- C[CR] or F[CR]

Read fluid pressure in PSI RP[CR] ----- ![CR]

Read fluid pressure in kPa RK[CR] ----- ![CR]

Read flow in GPM RG[CR] ----- ![CR]

Read flow in LPM RL[CR] ----- ![CR]

Read ambient temperature on PCB RA[CR] ----- ![CR]

110-279 44

Equipment Disposal (WEEE Directive)

or

This equipment is marked with the crossed out wheeled bin symbol to indicate it is covered by the Waste Electrical and Electronic Equipment (WEEE) Directive and is not to be disposed of as unsorted municipal waste. Any products marked with this symbol must be collected separately, according to the regulatory guidelines in your area.

It is your responsibility to correctly dispose of this equipment at lifecycle-end by handing it over to an authorized facility for separate collection and recycling. It is also your responsibility to decontaminate the equipment in case of biological, chemical and/or radiological contamination, so as to protect the persons involved in the disposal and recycling of the equipment from health hazards. By doing so, you will help to conserve natural and environmental resources and you will ensure that your equipment is recycled in a manner that protects human health.

Requirements for waste collection, reuse, recycling, and recovery programs vary by regulatory authority at your location. Contact your local responsible body (e.g., your laboratory manager) or authorized representative for information regarding applicable disposal regulations. Service and Technical Support If you have followed the troubleshooting steps and your Recirculating Chiller fails to operate properly, contact the supplier from whom the unit was purchased. Have the following information available for the customer service person:

• Model, Serial Number, and Voltage (from back panel) • Date of purchase and your purchase order number • Suppliers' order number or invoice number • A summary of your problem

110-279 45

PolyScience Chiller Fluids Circulating Bath Fluids Quantity Part Number

polyclean Algaecide 8 oz / 236 ml 004-300040

polyclean Algaecide Twelve 8 oz / 236 ml bottles 004-300041

polycool EG -25 (ethylene glycol) 1 gal / 4.5 liter 060340

polycool PG -20 (propylene glycol) 1 gal / 4.5 liter 060320

polycool HC -50 (water-based heat transfer fluid) 1 gal / 4.5 liter 060330

polycool MIX -25 (50/50 blend polycool EG -25 / H2O plus polyclean algaecide)

Five 0.5 gal / 2.27 liter bottles 004-300060

Warranty

NOTE: The Warranty on DuraChill and other custom-designed products applies only to the original end user and cannot be transferred or sold to another end user without written consent from the manufacturer.

The manufacturer’s warranty is one year for parts and labor and two years for parts. Please contact your supplier for additional warranty details and service contract information.

The manufacturer agrees to correct for the original user of this product, either by repair, or at the manufacturer's election, by replacement, any defect that develops after delivery of this product for the warranty period(s) stated above. In the event of replacement, the replacement unit will be warranted for 90 days or warranted for the remainder of the original unit’s parts or labor warranty period, whichever is longer. If a replacement unit is sent, the defective unit must be returned to the manufacturer within 30 days of receipt of the replacement unit. If the defective unit is not received within 30 days, the manufacturer reserves the right to bill for the replacement unit.

If this product requires service, contact the manufacturer/supplier's office for instructions. If return of the product is necessary, a return authorization number will be assigned and the product should be shipped, (transportation charges pre-paid), to the indicated service center. To insure prompt handling, the return authorization number should be placed on the outside of the package and a detailed explanation of the defect enclosed with the item.

This warranty shall not apply if the defect or malfunction was caused by accident, neglect, unreasonable use, improper service, or other causes not arising out of defects in material or workmanship. There are no warranties, expressed or implied, including, but not limited to, those of merchantability or fitness for a particular purpose which extends beyond the description and period set forth herein.

The manufacturer's sole obligation under this warranty is limited to the repair or replacement of a defective product and shall not, in any event, be liable for any incidental or consequential damages of any kind resulting from use or possession of this product. Some states do not allow: (A) limitations on how long an implied warranty lasts; or (B) the exclusion or limitation of incidental or consequential damages, so the above limitations or exclusions may not apply to you. This warranty gives you specific legal rights. You may have other rights that vary from state to state.

110-279 46

* DISCHARGE BYPASS VALVE ON7.5HP AND 10HP ONLY. WILL OPEN

FLOW DIAGRAMAIR-COOLED

*DISCHARGEBYPASS VALVE

FLUID PRESSURE

IN

DRAIN

SENSOR

WATER

WATER LEVELSIGHT GLASS

FROMPROCESS

RESERVOIR TANK

PUMP

TOPROCESS

RTD TEMPERATURESENSOR

BYPASSVALVE

FLOWMETER

LOWPRESSURESWITCH

15 PSI CO

SUCTIONLINE

30 PSI CI

COMPRESSOR

TXVTHERMOSTATIC

EXPANSION VALVE

FILTERDRIER SIGHT

GLASS

HOT GASBYPASS

PRESSURERELIEF VALVE

(675 PSI) "Y"STRAINER(WITH RESET

BUTTON)

REFRIGERANTHIGH

PRESSURESWITCH(630 PSI)

HAS TWO FANS, ONE WILL

REA

RPA

NEL

CONDENSER FAN(S)

5 & 7.5 HP HAVE ONE

ENGAGE WITH COMPRESSOR RUNNING, THE

PRESSURE CONTROLLED FANCUT IN AT 400 CUT OUT AT 300.

THE 10 HP

SECOND IS PRESSURE CONTROLLEDCUT IN AT 400 CUT OUT AT 300.

ON LOW HEAD PRESSURE ~120 PSI.

FANCYCLINGSWITCHTB1-1,3

Appendix Flow Schematic – Air-Cooled Chillers

110-279 47

VALVE

CONDENSER WATER FLOW

FLOW DIAGRAMWATER-COOLED

DW50015.4 USGPM / 58.3 LPM

FLUIDPRESSURE

IN

DRAIN

SENSOR

WATER

WATER LEVELSIGHT GLASS

FROMPROCESS

RESERVOIR TANKPUMP

TOPROCESS

TEMPERATURESENSOR

RTD

BYPASSVALVE

FLOWMETER

LOWPRESSURESWITCH

15 PSI CO

SUCTIONLINE

30 PSI CI

COMPRESSOR

TXVTHERMOSTATIC

EXPANSION VALVE

FILTERDRIER SIGHT

GLASS

HOT GASBYPASS

PRESSURERELIEF VALVE

(675 PSI) "Y"STRAINER(WITH RESET

BUTTON)

REFRIGERANTHIGH

PRESSURESWITCH(630 PSI)

REA

RPA

NEL

CONDENSERIN

CONDENSEROUT

"Y"STRAINER

CONDENSER

WATER REGULATING

20-40 PSI / 1.4-2.4 Bar Required

Flow Schematic – Water-Cooler Chillers

110-279 48

WIRING DIAGRAM - 5 & 7.5 HP CHILLERSAIR-COOLED

BLUYELYEL

BLKBLK

BLU NO

120VAC

NC

COM

WHTBLK

BLK

BLK

BLK

WHT

CRANKCASEHEATER

GBGRN/YEL

BLKWHT

FAN CYCLINGPRESSURE SWITCH

FAN

PHASEMONITOR

G

225-130SHUNT

REARPANEL

WHTBLK

WHTBLK

RED

BLK

BLK

17

12

15

23

10

3

9

7

21

6

8

20

24

16

18

19

13

1

4

11

22

2

14

5

2 1

12

12

12

122 12 12 12 1

12 12 12 12 12 12 13 213 213 234 1234 1234 1234 12

TB 3

FUSEBLOCK

CA

B D

CA

B D

YEL

9876

5432

1

GROUND BAR

TB 2

TB 2

TB 1

TB 1

STATUS ALARM CONTACTS

HOT GAS BYPASS VALVE

A2

A1

A2

A1

COMPRESSOR

PUMP

GRN/YEL

BLK

WHT

BLK

WHT

FLUID PRESSURE SENSOR

FLOW METER

REMOTE CUTOFF SWITCH

BLKBLK

YELYEL

BLUBLU

WHTBLURED

WHTWHT

BLK

BLU

REDGRNWHT

WHTGRNRED

WHT

BLK

RED

BLKGRN

BLKGRN

RED

REDWHTBLK

GRNBLK

GRN

REDWHTBLK

BRNBLK

POWERSUPPLY

GB

NC

NONC

NO

NO

NC

COMPRESSORPUMP

FUSEBLOCK

CONTACTOR

OVERLOAD RELAY

CONTACTOR

FUSEBLOCK

FAN

NC

FUSEBLOCK

OVERLOAD RELAY

NC

NO

A1

CONTACTOR

NO

A2

DISTRIBUTIONBLOCK

FRONT PANELDISCONNECT

SWITCH

L3L2L1

D

C

B

A

WHTBLK

YELGRN

RED

200-284

PCB U4 PIN 1PCB XFMR 1 PIN 10

PCB U4 PIN 4

215-513

31

125

200-280BEAD

GB

EMIFILTER

FAN

87 6

45

21

3

FAN(S) OVERLOAD RELAY (NC)

PUMP OVERLOAD RELAY (NC)

GB

DCMPDHRN PRK DPMP DFANPWR FAN HTR OTP CMP PMP

STA

1 2 3 4 56 87 912

123

1 2 3D232

RTD 100TEMP. SENSOR

1234HEFHITFPSDHPSDLPS RC

V

RCS

FLW

DAF2

DAP1

DAP2

DAF1

T3T2T1/ITS

5

3 421

CONT 5RS-232

637

4 2 1589

FLUID PRESSURESENSOR

FLOWMETER

BLKGRN

RED

HOTGAS

BYPASSVALVE

REFRIGERANT HIGHPRESSURE SWITCH

REFRIGERANT LOWPRESSURE SWITCH

13

3

16

2

21

6

9

7

2019

15

11

22

17

1

18

12

10

8

4

23 24

14

5

GBGB GB

L1 L2 L3JUNCTION BOX(REAR OF UNIT)

GROUND

SUPPLY VOLTAGEOUTPUT

OUTPUTGROUND

SUPPLY VOLTAGE

COMNO

NC

NCCOMNO

12

FAN

BLK WHT BLUBRN

FLOWSWITCH

RCFILTER

RCFILTER

RCFILTER

525-814PULLUP

RESISTORS

RJ-45

1.4A

1.4A

3.5A

MULTI -TAPTRANSFORMER

120VAC OUTPUT

GB

FUSEBLOCK

BLK

WHT

Wiring Diagram – 5 HP and 7.5 HP Air-Cooled Chillers

110-279 49

WIRING DIAGRAM - 10 HP CHILLERS

BLK

BLUBLU

RCFILTER

COM

NC

120VAC

NO

BLKBLK

YELYEL

BLUBLU

WHT

BLK

GRN/YELGB

CRANKCASEHEATER

FRONT FAN

RJ-45

PULLUP

RESISTORS

525-814

FUSE

BLOCK

GB


120VAC OUTPUT

3.5A

1.4A

1.4A

A1

RCFILTER

RCFILTER

RCFILTER

CONTROL PCB500-328A-A

PHASEMONITOR

FLOWSWITCH

BRNBLU

WHTBLKBLK

REAR FAN

PANEL

21

NOCOMNC

NC

NOCOM

SUPPLY VOLTAGEGROUNDOUTPUT

OUTPUT

SUPPLY VOLTAGEGROUND

JUNCTION BOX(REAR OF UNIT)

L1 L2 L3 GND

GBGB GBGB

5

14

2423

4

8

10

12

18

1

17

22

11

15

19 20

7

9

6

21

2

16

3

13

FAN CYCLINGPRESSURE SWITCH



HOT GASBYPASSVALVE

RED

GRNBLK

FLOW METER


9 85 124

73

6

RS-232CONT 5

12 4

3

5

T1/ITS T2 T3

DA

F1

DA

P2

DA

P1

DA

F2

FLW

RCS

RCVDLPS DHPS FPS HIT HEF

4 3 2 1

RTD 100TEMP. SENSOR

D232321

3 2 1

2 197 8654321

STA

PMPCMPOTPHTRFANPWRDFANDPMPPRKDHRN DCMP

GB


FAN(S) OVERLOAD RELAY (NC)

3

1

2

54

67

8

FAN

EMIFILTER

GB

200-280BEAD

521

13

215-513


PCB U4 PIN 1

200-284

RED

GRNYEL

BLK

WH

T

A

B

C

D

L1 L2 L3


SWITCH

DISTRIBUTIONBLOCK

A2

NO

CONTACTOR CONTACTOR

NO

NC

OVERLOAD RELAY

OVERLOAD RELAY

FUSEBLOCK

FUSEBLOCK

NC

FRONTFAN

REARFAN

NC

NC

NO

NO

FUSEBLOCK

CONTACTOR

OVERLOAD RELAY

CONTACTOR

FUSEBLOCK

PUMP COMPRESSOR

NC

NO

NO

NC

NO

NC

GB

POWERSUPPLY

BLKBRN

BLKWHTRED

GRN

BLKGRN

BLKWHTRED

RED

GRNBLK

GRNBLK

RED

WHT

BLK

WHT

REDGRNWHT

WHTGRNRED

BLK

BLK

BLU

BLK

WHTWHT

REDBLUWHT

BLUBLU

YELYEL

BLKBLK


FLOW METER

FLUID PRESSURE SENSOR WHT

BLK

WHT

BLK

GRN/YEL

PUMP

COMPRESSOR

A2

A1A1

A2

A1

A2

BLUBLU



TB 1

TB 1

TB 2

TB 2

GROUND BAR

1

2345

6789

YEL

DB

A C

DB

A C

FUSEBLOCK

TB 3

2 14 3 2 14 3 2 14 3 2 14 3 23 1 23 1 23 12 12 12 12 12 12 1

12 12 12 12 21

21

21

21

12

5

14

2

22

11

4

1

13

19

18

16

24

20

8

6

21

7

9

3

10

23

15

12

17

BLK

BLK

RED

BLKWHT

BLKWHT

BLK

REAR

FRONT FAN

Wiring Diagram – 10 HP Air-Cooled Chillers

110-279 50

WHT

COM

NC

120VAC

NOBLU

BLK

BLK

YELYELBLU

1.4A

1.4A

3.5A


120VAC OUTPUT

GB

FUSEBLOCK

PHASEMONITOR

G

225-130SHUNT

REARPANEL

WHTBLK

WHTBLK

RED

BLK

BLK

17

12

15

23

10

3

9

7

21

6

8

20

24

16

18

19

13

1

4

11

22

2

14

5

2 1

12

12

12

122 12 12 12 1

12 12 12 12 12 12 13 213 213 234 1234 1234 1234 12

TB 3

FUSEBLOCK

CA

B D

CA

B D

YEL

9876

5432

1

GROUND BAR

TB 2

TB 2

TB 1

TB 1



A2

A1

A2

A1

COMPRESSOR

PUMP

GRN/YEL

BLK

WHT

BLK

WHT

GRN/YEL

BLK

WHT

FLUID PRESSURE SENSOR

FLOW METER


YELYEL

WHTBLURED

WHTWHT

BLK

BLU

REDGRNWHT

WHTGRNRED

WHT

BLK

RED

BLKGRN

BLKGRN

RED

REDWHTBLK

GRNBLK

GRN

REDWHTBLK

BRNBLK

POWERSUPPLY

GB

GB

NC

NO

NC

NO

NO

NC

COMPRESSORPUMP

FUSEBLOCK

CONTACTOR

OVERLOAD RELAY

CONTACTOR

FUSEBLOCK

DISTRIBUTIONBLOCK


SWITCH

L3L2L1

D

C

B

A

WHTBLK

YELGRN

RED

200-284


PCB U4 PIN 4

215-513

31

125

200-280BEAD

GB

EMIFILTER

CRANKCASEHEATER

FAN

87 6

45

21

3


GB

DCMPDHRN PRK DPMP DFANPWR FAN HTR OTP CMP PMP

STA

1 2 3 4 56 87 912

123

1 2 3D232

RTD 100TEMP. SENSOR

1234HEFHITFPSDHPSDLPS RC

V

RCS

FLW

DAF2

DAP1

DAP2

DAF1

T3T2T1/ITS

5

3 421

CONT 5RS-232

637

4 2 1589


FLOWMETER

BLKGRN

RED

HOTGAS

BYPASSVALVE



13

3

16

2

21

6

9

7

2019

15

11

22

17

1

18

12

10

8

4

23 24

14

5

GB GB

L1 L2 L3JUNCTION BOX(REAR OF UNIT)

GROUND

SUPPLY VOLTAGEOUTPUT

OUTPUTGROUND

SUPPLY VOLTAGE

COMNO

NC

NCCOMNO

12

BLK WHT

BLUBRN

FLOWSWITCH

RCFILTER

RCFILTER

525-814PULLUP

RESISTORS

RJ-45

WIRING DIAGRAM - 5 HP CHILLERSWATER-COOLED

BLU BLU

Wiring Diagram – 5 HP Water Cooled Chillers

110-279 51

4-20 mA Set Point Control This feature is optional and may not appear in your version of software. To enable it, go the Current Control (CC) in the Operational Parameters menu and set to YES.

If current input is outside 4-20 mA, ECC (Error Current Control) will be displayed and the pump, compressor, and fan will turn Off. Sending an in-range input will restart the Chiller.

0.32 mA per °C 0.1778 mA per °F

°C mA °C mA °C mA °F mA °F mA °F mA °F mA °F mA -10 4.000 7 9.440 24 14.880 14 4.000 33 7.378 52 10.756 71 14.133 90 17.511 -9 4.320 8 9.760 25 15.200 15 4.178 34 7.556 53 10.933 72 14.311 91 17.689 -8 4.640 9 10.080 26 15.520 16 4.356 35 7.733 54 11.111 73 14.489 92 17.867 -7 4.960 10 10.400 27 15.840 17 4.533 36 7.911 55 11.289 74 14.667 93 18.044 -6 5.280 11 10.720 27 16.160 18 4.711 37 8.089 56 11.467 75 14.844 94 18.222 -5 5.600 12 11.040 29 16.480 19 4.889 38 8.267 57 11.644 76 15.022 95 18.400 -4 5.920 13 11.360 30 16.800 20 5.067 39 8.444 58 11.822 77 15.200 96 18.578 -3 6.240 14 11.680 31 17.120 21 5.244 40 8.622 59 12.000 78 15.378 97 18.756 -2 6.560 15 12.000 32 17.440 22 5.422 41 8.800 60 12.178 79 15.556 98 18.933 -1 6.880 16 12.320 33 17.760 23 5.600 42 8.978 61 12.356 80 15.773 99 19.111 0 7.200 17 12.640 34 18.080 24 5.778 43 9.156 62 12.533 81 15.911 100 19.289 1 7.520 18 12.960 35 18.400 25 5.956 44 9.333 63 12.711 82 16.089 101 19.467 2 7.840 19 13.280 36 18.720 26 6.133 45 9.511 64 12.889 83 16.267 102 19.644 3 8.160 20 13.600 37 19.040 27 6.311 46 9.689 65 13.067 84 16.444 103 19.822 4 8.480 21 13.920 38 19.360 28 6.489 47 9.867 66 13.244 85 16.622 104 20.000 5 8.800 22 14.240 39 19.680 29 6.667 48 10.044 67 13.442 86 16.800 6 9.120 23 14.560 40 20.000 30 6.844 49 10.222 68 13.600 87 16.978 31 7.022 50 10.400 69 13.778 88 17.156 32 7.200 51 10.578 70 13.956 89 17.333

110-279 DuraChill Chillers 5-10HP 6-10-2015 · Operator’s Manual ... 14 Signal Inputs ... Chiller...

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Transcript of 110-279 DuraChill Chillers 5-10HP 6-10-2015 · Operator’s Manual ... 14 Signal Inputs ... Chiller...