HP Refrigerated Recirculating Chillers User's Manual
Contents
1. Operators Manual ing Chillers lat ircu Refrigerated Rec Powerful Cool Microprocessor Controller Digital Set amp Read with E E 2 AO Tan i amp 2 vs DE a l 5 SY E a NN 0 a 3 25 onr L O 2 ro A FASISSALISISISIZIPLISSMI FILAISILIFISISCISILOLICO A 110 116 rev D ecn 1390 A Table of Contents Section 1 General Information 1 1 Warranty 1 2 Unpacking 1 3 Package Contents 1 4 Description 1 5 Specifications and Pump Performance Section 2 Set Up 2 1 Location 2 2 Reservoir Fluids 2 3 Pump Hoses and Couplings 2 4 Setting Up a Closed System or Cooling Coil to the Chiller 2 5 Setting Up an Open Bath System to the Chiller FEVTTTILGLAPRTTASE IASI TE Section 3 Operation 3 1 Power Requirements 3 2 Temperature Setting and Adjustments 3 3 Selection of Celsius or Fahrenheit 3 4 Setting the Readout High Limit 3 5 Controller Display Messages 3 6 Draining the Unit 3 7 Controller Default Settings Section 4 Diagram of Models Section 5 Maintenance 5 1 Standard Magnetic Drive Centrifugal Pump Motor 5 2 Positive Displacement High Pressure Pump Motor 5 3 Fluid Filter Included With High Pressure Pump 5 4 Refrigeration Air Vents amp Air Filter Section 6 Troubleshooting 6 1 Unit Disabled 6 2 No Pumping 6 3 Insufficient Pumping 6 4 No Cooling or Insufficient Cooling This symbol marks chapters and sections of this instruction manual which are pa2. Run the unit intermittently 5 to 10 seconds each time to pump the water from the system Stop pumping when the fluid is reduced to a trickle Running for a longer period will cause damage to the positive displacement pump Open the reservoir and use suction or a hand pump to remove any remaining water Prior to storage or shipping Water MUST be removed from ALL parts of the chiller system or an ANTIFREEZE must be added to insure that internal damage does not occur 3 7 Controller Default Settings To return to the factory default values 1 Press and hold the Power On button then turn off at the circuit breaker Still holding Power On hold the Set Menu button while turning the unit on by the circuit breaker The controller will display DEF and go to the standby mode Pi N Your set temperature and other settings will have to be reset Section 4 Diagram of Models Top Cover To Access AT PROVISION FOR 15 OR 9 PIN FEMALE CONNECTOR 6705 amp 6105 RESERVOIR Circuit REGULATOR PROBE Rear Access PANEL PRESSURE TEMPERATURE INLET Fluid In OUTLET Fluid Out DRAIN Top Cover To Access RESERVOIR SILILISILILISIZIONELLE LALELIIFETILIIALIVASAI ALILLIFETILEIIIAILIZIE tiII EEEIEI A BREAKER LINE VOLTAGE IEC 320 CONNECTOR 6205 amp 6305 amp 6505 Top Cover To Access RESERVOIR TEMPERAT
3. and unplug the chiller Remove the rear access panel to gain access to the pump With heavy use oil every year With medium use oil every 3 years With light use oil every 5 years Use about 150 drops 1 teaspoon of SAE 20 oil in each bearing On models 6105 6705 and 6155 remove the right side panel to access the pump 5 3 Fluid Filter Included With High Pressure Pump To optimize flow and prevent pump damage due to scale or foreign particles a filter is included with the high pressure pump models How often the filter requires maintenance depends on the environment and use of the chiller To access this filter remove the left side panel The water filter is located behind the side brace Grip the plastic sediment bowl firmly and turn counter clockwise to remove it Clean the stainless steel wire screen found inside and replace it in the filter holder Do not replace the filter screen unless it is damaged On models 6105 and 6705 remove the right side panel to access the water filter and pump On model 6155 you must remove the top panel in order to remove the side panel After removing the side panel you will have access to the water filter 5 4 Refrigeration Air Filter amp Air Vents For maximum cooling efficiency the condenser and the front and back air vents should be kept free of dust and dirt Dirt thermally insulates the condenser coils and reduces the cooling capacity of the refrigeration system Set up a periodic sche
4. located to the right On models 6107 amp 6705 6155 the regulator is located center point upper grille rear The Pressure Valve is FACTORY ADJUSTED to 40psi If you do NOT want to operate at this pressure or do not know what your operating pressure should be start at a lower operating pressure Reduce the pressure by turning the valve counterclockwise unscrew outward before starting the chiller With the chiller fully connected and running read the pressure gauge and turn the regulator to the desired pressure If required an optional external pressure reducing assembly is available for this pump to reduce the pressure to 10 45 psi 2 4 Setting Up a Closed System or Cooling Coil to the Chiller 1 Connect your closed cooling system to the chiller with hoses or pipes The direction of the flow through the system can be controlled by the way the hoses or pipes are connected to the chiller The Inlet will draw liquid into the chiller the Outlet will pump liquid out 2 Turn the access panel screws to remove the top cover and expose the reservoir Turn the filler cap and lift up to remove Use a funnel to fill the reservoir with fluid When full remove the funnel but do not replace the cap at this time Check hoses and fittings for tightness and be sure there are no bends or crimps in the hoses 3 Plug the chiller into the proper AC outlet unit s electrical requirements on rear of unit Press the Power ON button T
5. of Inlet Outlet Adapters 1 2 inch I D tubing 5 8 inch I D tubing Durable Tubing 1 2 inch I D 1 4 Description These chillers provide cooling power for demanding applications and economically replace tap water cooling systems All models have a microprocessor controller digital set read and readout in C or F The refrigeration system has modulation capability to provide cooling as needed and thus greater temperature stability and longer compressor life Wetted parts are brass copper polypropylene PVC nylon and stainless steel 1 5 Chiller Specifications and Pump Performance General Specifications To All Chillers Temperature Setability 0 1T Temperature Uniformity 0 5T Readout Selectability C or F Pump Inlet amp Outlet 1 5 inch NPT Pump Performance 76 6 9 100 68 ui 907 so tz 60 He 50 Hz 60 Hz 62 5 5 80 1 55 48 70 van HIP 48 o 3 3 4 HP g oer ao 1 4 HP a 2 z g z g G34 2 50 35 g i a 5 27 3 40 25 a 2 0 30 220 13 20 14 10 07 0 o Or 2 Gal per min 0 05 1 15 2 25 3 35 4 45 5 Gal per min 0 2 4 6 8 10 12 14 16 Lit miso 38 76 11 4 152 Literspermin 0 7 6 15 2 22 8 308 380 45 6 53 2 Mera ROE Mini i i Centrifugal Pump Capacity Positive Displacement Pump Capacity Comparison of Pump Options Positive Displacement Pump i 20 Reg
6. BE USED A Do not use a flammable fluid as a fire hazard may result A WARNING Operation below 15 C requires antifreeze in the circulating fluid 2 3 Pump Hoses and Couplings To maintain a safe workplace and to avoid leaks special care should be taken when choosing hoses and connectors for the chiller 1 Pressure ratings Hoses should be able to withstand the largest pressure that they will encounter For positive displacement pump models this is 100 psi 2 Flexible tubing Avoid tubing that will expand and take up fluid volume when operating at the desired pressure 3 Hose diameter The fittings on the chiller Outlet and Inlet lines are internally threaded 1 2 inch I D N P T The 2 adapters sets supplied are for 1 2 inch I D tubing and 5 8 inch I D tubing Other fittings can be used if a smaller hose diameter is desired Remember that the operating pressure in the circulating system increases when using a smaller diameter hose 4 Couplings amp Clamps The use of screw tightened hose clamps is necessary on all joints to insure good tight connections Quick connectors are not recommended because they have the potential for restricting flow rate IMPORTANT Chillers equipped with a high pressure positive displacement pump have a pressure regulator inside of the chiller and a pressure gauge on the control panel To access this regulator remove the rear air grille The valve is
7. URE PROBE Access PLUG 9 Pin FEMALE CONNECTOR CIRCUIT BREAKER IEC 320 a O E oh Go u gt u z z 20 lt 9 z Qi CI oz an Q A N NNS SAN VO A FILIERAFISITISHZIRIITISS IILILIAISSIISISISILIZISA LLICIPIEISIVILIALI FILI TO CALILLEACELITALLICIIOLET PILLIETELIZILILIFSSISALI FASESANIIIIASSISFDIPLTISIA LFILISEIALISITCISILULIAI amp OUTLET Fluid Out REAR Access PANEL Air FILTER dtttititiittttittitittit ut TOP COVER TO ACCESS RESERVOIR AIR FILTER ae TOP COVER p19 ACCESS RESERVOIR CIRCUIT BREAKER NLET Fluid in PROVISIONS FOR 15 AND 9 PIN we FEMALE CONNECTOR ae ran n ITH LOCKING OUTLET QUIET CONNECTOR LINE VOLTAGE DRAIN 12 Section 5 Maintenance Prepare a schedule to perform these specific maintenance tasks at their recommended intervals 5 1 Standard Magnetic Drive Centrifugal Pump Motor When the chiller is used continuously this pump motor must be oiled every 6 months with SAE 20 oil Press the Power OFF and unplug the chiller Remove the rear access panel to gain access to the two oil ports located on the pump motor Do not apply excessive amounts of oil On models 6105 6705 and 6155 remove the side panel to access the pump 5 2 Positive Displacement and Turbine High Pressure Pump Motor The bearings of the pump require periodic oiling Press Power OFF
8. controller is performing a self diagnostic and a balancing of pressure across the compressor inlet and outlet a balanced system reduces the AC current required to start up the compressor and will result in an extended compressor life The pump is active during the start delay period When the time out period reaches zero the compressor starts and the chiller is then fully operational Upon completion of the self test the actual fluid temperature is displayed Your desired operating temperature can now be set 2 Press the Ser Menu button The degree lights flash indicating the temperature can be set or changed Turn the SETTING ADJUSTMENT knob to the desired setting This setting is accepted after pressing the SET MENU button or will be automatically accepted after a few seconds of keypad inactivity The degree light stops flashing and the display shows the actual temperature 3 The Set TEMPERATURE may be checked at any time by pressing and releasing the SET MENU button Allow sufficient time for the chiller to stabilize at the desired temperature 3 3 Selection of Celsius or Fahrenheit To change the readout to C or F 1 Press and hold the Set Menu button until the display reads UNITS 2 Press Set Menu again then turn the Setting Adjustment knob and select C or F 3 Press Set Menu or the setting will be accepted after a few seconds 3 4 Setting the Readout High Limit This feature limits the readout setability so the operat
9. ctrical data Cooling Capacity Watts x 3 41 BTUs hr Performance specifications determined at ambient temperature of 20 C 68 F For 50Hz models derate cooling capacity and pump flow by 17 External Pressure Reducing Assembly for Positive Displacement Pump models Steps down high outlet pressure to 10 to 45 psi Cat No 060302 6 Section 2 Set Up A Before proceeding be sure all power is off 2 1 Location Locate the chiller on a strong level surface Insure easy access to the top cover and position the chiller for unobstructed air flow through the front and rear screens The front wheels can be locked to keep the chiller in place while in use Avoid voltage drops by using properly grounded power outlets wired with 14 gauge or larger diameter wire If possible be close to the power distribution panel Minimize low line voltage problems by eliminating the use of extension cords 2 2 Reservoir Fluids For most applications above 15 C distilled water is satisfactory For operation below 15 C the chiller MUST be protected with an antifreeze solution Ethylene glycol laboratory grade and water in a 50 50 mixture is satisfactory from 15 C to 15 C Select a fluid that is compatible with the chiller s wetted parts of brass copper polypropylene PVC nylon and stainless steel Only use fluids that will satisfy safety health and equipment compatibility requirements CAUSTIC CORROSIVE OR FLAMMABLE FLUIDS MUST NEVER
10. derate cooling capacity and pump flow by 17 External Pressure Reducing Assembly for Positive Displacement Pump models Steps down high outlet pressure to 10 to 45 psi Cat No 060302 5 6000 Series Standard Chillers with Magnetic Drive Centrifugal Pump Model 6705 6105 6155 Operating Temperature 15 to 40 15 to 40 C 5 to 35 C Compressor 3 4 hp 1hp 1 hp 20T 2500 Watts 20T 2850 Watts 10T 1700 Watts 10T 1925 Watts 10T 3600 Watts 0C 760 Watts 0T_ 940 Watts 5 C 2700 Watts Cooling Capacity 20 5200 Watts Pressure at 0 Flow Rate 10 psi 10 psi 10 psi Flow Rate 0 psi 4 3 gpm 16 3 lpm 4 3 gpm 16 3 lpm 4 3 gpm 16 3 lpm Reservoir Capacity 1 65 gal 6 25 liters 1 65 gal 6 25 liters 6 25 gal 23 65 liters Dimensions in 24 x 143 g x 261 2 24 x 148 g x 261 2 30 x 21x 27 hxwxd cm 61 x 36 5 x 67 3 61 x 36 5 x 67 3 76 2 x 53 3 x 68 6 Shipping Weight 178 lbs 178 lbs 450 lbs Volts Hz Amps 208 230V 60Hz 7 5A 208 230V 60Hz 8A 208 230V 60Hz 12A Volts Range 187V to 253V 187V to 253V 187V to 253V 60Hz Cat No 080531 080542 080593 Volts Hz Amps 240V 50Hz 7 5A 240V 50Hz 8 5A 240V 50Hz 12A Volts Range 198V to 264V 198V to 264V 198V to 264V Over Voltage Category Il 50Hz Cat No 080536 080546 080594 Additional Specifications for P Series 6000 Chillers with Positive Displacement Pump Model P Series 6705P 6105P 6155P Flow Rat
11. dule to clean the removable air filter at least monthly Tap water and mild detergent is sufficient to clean filter material Frequency of cleanings depends on the atmospheric conditions around the chiller as well as length of operating time
12. e 0 psi 4 gpm 15 2 Ipm 4 gpm 15 2 Ipm 4 gpm 15 2 Ipm Pump Pressure Adjustable 20 to 100psi 20 to 100psi 20 to 100psi Shipping Weight 178 lbs 178 lbs 450 lbs Volts Hz Amps 208 230V 60Hz 10A 208 230V 60Hz 11A 208 230V 60Hz 12A Volts Range 187V to 253V 187V to 253V 187V to 253V 60Hz Cat No 080532 080544 080596 Volts Hz Amps 240V 50Hz 10A 240V 50Hz 11A 240V 50Hz 12A Volts Range 198V to 264V 198V to 264V 198V to 264V Over Voltage Category Il 50Hz Cat No 080537 080547 080597 Additional Specifications for T Series 6000 Chillers with Turbine Pump Model T Series 6705T 6105T 6155T Flow Rate 0 PSI 3 5 gpm 13 2 lpm 3 5 gom 13 2 lpm 3 5 gpm 13 2 lpm Pump Pressure Adjustable 20 to 100psi 20 to 100psi 20 to 100psi Volts Hz Amps 208 230V 60Hz 9 6A 208 230V 60Hz 10 8A 208 230V 60Hz 12A Volts Range 108V to 132V 108V to 132V 187V to 253V 60Hz Cat No 080533 080543 080598 Volts Hz Amps 240V 50Hz 9 6A 240V 50Hz 10 8A 240V 50Hz 12A Volts Range 198V to 264V 198V to 264V 198V to 264V Over Voltage Category Il 50Hz Cat No 080538 080548 080599 Environmental Conditions Indoor Use Only e Maximum Altitude 2000 meter Operating Ambient 5 to 30 C Relative Humidity 80 for temperatures to 30 C e Pollution Degree 2 e Class 1 Residential Commercial Light Industrial Class 2 Heavy Industrial Notes Refer to the serial number plate on rear of the chiller for model and ele
13. enerative Turbine Pump 15 Head Pressure PSI Centrifugal Pump Flow Rate GPM 6000 Series Standard Chillers with Magnetic Drive Centrifugal Pump Model 6205 6305 6505 Operating Temperature 5 to 40T 5 to 40T 10 to 40 Compressor 1 4 hp 1 3 hp 1 2 hp Cooling Capacity 20 C 750 Watts 1200 Watts 1320 Watts 10 450 Watts 825 Watts 1055 Watts 0c 100 Watts 375 Watts 550 Watts Pressure at 0 Flow Rate 10 psi 10 psi 10 psi Flow Rate 0 psi 4 3 gpm 16 3 lpm 4 3 gpm 16 3 lpm 4 3 gpm 16 3 lpm Reservoir Capacity 1 65 gal 6 25 liters 1 65 gal 6 25 liters 1 65 gal 6 25 liters Dimensions in 24 x 143 8 x 261 2 24 x 143 8 x 261 2 24 x 143 8 x 261 2 hxwxd cm 61 x 36 5 x 67 3 61 x 36 5 x 67 3 61 x 36 5 x 67 3 Shipping Weight 155 lbs 165 lbs 170 lbs Volts Hz Amps 120V 60Hz 6 8A 120V 60Hz 8A 120V 60Hz 13A Volts Range 108V to 132V 108V to 132V 108V to 132V 60Hz Cat No 080501 080511 080521 Volts Hz Amps 240V 50Hz 3 4A 240V 50Hz 4A 240V 50Hz 6 5A Volts Range 198V to 264V 198V to 264V 198V to 264V Over Voltage Category Il 50Hz Cat No 080506 080516 080526 Additional Specifications for P Series 6000 Chillers with Positive Displacement Pump Model P Series 6205P 6305P 6505P Flow Rate 0 psi 1 gpm 3 8 Ipm 1 gpm 3 8 lpm 1 gpm 3 8 lpm Pump Pressure Adjustable 20 to 100psi 20 to 100psi 20 to 100psi Sh
14. he chiller will begin pumping liquid through your system Check for leaks 4 With the pump running the reservoir s fluid level will decrease as the closed system begins to fill Add a little fluid at a time until the level in the reservoir stops going down This means that your system is filled and the air has been purged from it Replace the reservoir cap and turn it clockwise to lock it Recheck the cap for tightness Note When chillers with the standard magnetic drive centrifugal pump are connected to an external apparatus with a built in flow shut off an external bypass loop assembly pt 510 147 may be needed if operating below 20 C This bypass assembly continues fluid circulation to and from the pump even though the main flow to the external apparatus has been blocked 2 5 Setting Up an Open Bath System to the Chiller 1 Connect hoses to the Inlet and Outlet fittings on the back of the chiller The Inlet draws fluid into the chiller the Outlet pumps fluid out Fill the open bath Considering this flow position the hoses in your bath for a good circular flow and stirring motion 2 Turn the panel screws to remove the top cover and access the reservoir Turn and lift the filler cap to remove Use a funnel to fill the reservoir with the same fluid in your bath This primes the pump and helps establish a flow when the chiller is turned on 3 Replace the reservoir cap and turn to lock it Check for tightness Check all hoses and fi
15. ing temperature setting cannot easily be set above the High Limit you select It is not an over temperature feature which shuts off the chiller To set the readout High Limit 1 Press and hold the Set Menu button until the display reads UNITS Turn the Setting Adjustment knob until the display reads HI L Press the Set Menu button enter the desired value using the Setting Adjustment knob PN Press Set Menu and the display will again read HI L The Setting Adjustment knob can be turned to access another menu option or you can wait until the entered value has been accepted When the value is accepted the degree light will stop flashing and the fluid temperature will be displayed 3 5 Controller Display Messages Display Message Normal Screens Standby mode Unit plugged in Power switch OFF rear circuit breaker on 8888 Power up self test displayed when power button initially pressed on Menu Screen Unit Change to F or C Unit Hi L Limits operating temperature setability Error Screens E tF Triac alternistor failure DEF Displayed when chiller is reset to factory default settings Optional Equipment Flow or Float Switch E nF No Flow E FL Low Level Fluid 3 6 Draining the Unit Press the Power Off button and unplug the chiller Remove drain plug and reservoir cap and allow unit to drain Syphon or use a small manual pump to remove all fluid from the reservoir
16. ipping Weight 160 lbs 170 lbs 170 lbs Volts Hz Amps 120V 60Hz 9 6A 120V 60Hz 10 8A 120V 60Hz 15 8A Volts Range 108V to 132V 108V to 132V 108V to 132V 60Hz Cat No 080502 080512 080522 Volts Hz Amps 240V 50Hz 4 8A 240V 50Hz 5 4A 240V 50Hz 8A Volts Range 198V to 264V 198V to 264V 198V to 264V Over Voltage Category Il 50Hz Cat No 080507 080517 080527 Additional Specifications for T Series 6000 Chillers with Turbine Pump Model T Series 6205T 6305T 6505T Flow Rate 0 PSI 3 5 gpm 13 2 Ipm 3 5 gpm 13 2 Ipm 3 5 gpm 13 2 Ipm Pump Pressure Adjustable 20 to 100psi 20 to 100psi 20 to 100psi Volts Hz Amps 120V 60Hz 9 6A 120V 60Hz 10 8A 120V 60Hz 15 8A Volts Range 108V to 132V 108V to 132V 108V to 132V 60Hz Cat No 080503 080513 080523 Volts Hz Amps 240V 50Hz 4 8A 240V 50Hz 5 4A 240V 50Hz 8A Volts Range 198V to 264V 198V to 264V 198V to 264V Over Voltage Category Il 50Hz Cat No 080508 080518 080528 Environmental Conditions Indoor Use Only e Maximum Altitude 2000 meter Operating Ambient 5 to 30 C Relative Humidity 80 for temperatures to 30 C Pollution Degree 2 Class 1 Residential Commercial Light Industrial Class 2 Heavy Industrial Notes Refer to the serial number plate on rear of the chiller for model and electrical data Cooling Capacity Watts x 3 41 BTUs hr Performance specifications determined at ambient temperature of 20 C 68 F For 50Hz models
17. rticularly relevant to safety Section 8 Replacement Parts When attached to the unit this symbol draws attention to the relevant section of the instruction manual Section 7 Service and Technical Support This symbol indicates hazardous voltages may be present Section 1 General Information 1 1 Warranty Thank you for your purchase We are confident it will serve you for a long time Our warranty to you is as follows 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 which develops after delivery of this product within the period as stated on the warranty card 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 this product should require service contact the manufacturer suppliers office for instructions When 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 ser
18. ttings Be sure there are no bends or crimps in the hoses and that the hose attached to the chiller s inlet is submerged near the bottom of the bath Secure the inlet and outlet hoses to the open tank so they do not move when pumping starts The bath s fluid level will drop slightly as the hoses in the system fill up with fluid The bath s fluid must cover the chiller s inlet hose 4 Plug the unit into the proper AC outlet unit s electrical requirements on rear of unit Press the Power On button The chiller will begin pumping fluid through your system Check for leaks Section 3 Operation 3 1 Power Requirements A N Caution Be sure that the power supply is the same voltage as specified on the nameplate With the chiller plugged in before pressing the Power ON button the display responds by showing standby If there is no response check that the circuit breaker on the rear of the chiller is in the ON position An extension cord is not recommended For models with LED C OR F SETTING optional heater only Display Display ADJUSTMENT KNOB PRESSURE GAUGE SeT MENU POWER On Positive Displacement BUTTON BUTTONS Pump models only Front Face Plate 3 2 Temperature Setting and Adjustments After setting up and filling the chiller 1 Press the Power ON button The LED display indicates 8888 the power up self test When the chiller is turned on there is a 60 second time out period During this time the
19. vice 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 the manufacturer 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 which vary from state to state 1 2 Unpacking Your recirculating chiller is shipped in a special carton Retain the carton and all packing materials until the unit is completely assembled and working properly Set up and run the unit immediately to confirm proper operation Beyond one week your unit may be warranty repaired but not replaced If the unit is damaged or does not operate properly contact the transportation company file a damage claim then contact the company where your unit was purchased 1 3 Package Contents Recirculating Chiller Operators Manual Warranty Card 2 sets
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