Conair 0.25 to 1.5 ton User's Manual
Contents
1. GENERAL 1 Make certain all ground connections to the unit are properly affixed 2 Make certain power conductor disconnect device and fusing are properly sized according to the unit s power supply requirements 3 Make certain all electrical connections are tightly affixed Any loose wiring connections must be tighten before engaging the power supply 4 Make certain no moisture or standing water is present inside the electrical cabinet Microprocessor Illuminated on off controller Transformer switch Motor starter Page 12 VL Series Portable Chillers 0 25 to 1 5 Tons UGH020 0301 3 0 OPERATIONS 3 1 GENERAL 3 2 START UP OPERATIONS PROCEDURE 3 3 INSTRUMENT OPERATION 3 4 SHUT DOWN DISCONNECT SEQUENCE UGH020 0301 VL Series Portable Chillers 0 25 to 1 5 Tons Page 13 3 1 GENERAL A Failure to follow the factory required operation procedures may adversely affect the unit s ability to control process temperature and may create a hazardous operating condition which may result in unit damage and serious operator injury or death B The Operations segment of this manual is outlined below 3 2 Machine start up operations procedure follow this segment to start the unit after the initial installation or to restart the unit after reinstallation to the same or different process This section includes information on system fill electric motor phasing pump rotation and process flow adjustments 3 3 Instrument f2. User Guide Portable Chillers VL Series 0 25 to 1 5 ton models CONAIR One Conair Drive arts Pittsburgh PA 15202 80 Phone 412 312 6000 Fax 412 312 6227 UGH020 0301 Please record your _ It s a good idea to record the model and serial number s of eguipment s model and your equipment and the date you received it in the User serial number s and Guide Our service department uses this information along the date you received it with the manual number to provide help for the specific in the spaces provided equipment you installed Please keep this User Guide and all manuals engineering prints and parts lists together for documentation of your equipment Manual Number UGH020 0301 Serial number s Model number s DISCLAIMER The Conair Group Inc shall not be liable for errors contained in this User Guide or for incidental consequential dam ages in connection with the furnishing performance or use of this information Conair makes no warranty of any kind with regard to this information including but not limited to the implied warranties of merchantability and fitness for a particular purpose Copyright 2001 THE CONAIR GROUP INC All rights reserved TABLE OF CONTENTS 1 0 2 0 3 0 4 0 5 0 6 0 7 0 8 0 UGH020 0301 GENERAL 1 1 Unit location 1 2 Efficiency 1 3 Safety 1 4 Clean air act 1 5 Miscellaneo
3. Air flow is from the outside of the chiller through the condenser and exhausted through the unit Exhaust air can not be ducted on motor driven fan models A free air space of at least four 4 feet is required at the condenser intake and four 4 feet at the condenser discharge to allow for proper air flow At full load this chiller will discharge approximately 15 000 BTU hr per hour per ton of cooling VL Series Portable Chillers 0 25 to 1 5 Tons Page 11 2 5 ELECTRICAL CONNECTION A NEMA 1 MODELS 1 Electrical power supply requirements for Nema 1 units figure 2 5A are identified on the equipment data plate Verify that available voltage supply is the same as the unit s voltage requirements WARNING Do not connect the unit to a voltage supply source not equal to the unit s voltage requirements as specified on the data plate Use of incorrect voltage will void the unit s warranty and cause a significant hazard that may result in serious personal injury and unit damage 2 A factory supplied four conductor cable is installed for connection to a customer supplied fused power disconnect device The fused disconnect device shall be sized and installed according to the unit s power supply requirements and local electrical codes CONTROL CIRCUIT WIRING 1 The unit s supplied control circuit is indicated in the electrical diagrams The control circuit is supplied by the factory installed transformer
4. BTU HR GPM x 500 x water H D PSI x 2 31 1 COOLING TOWER TON 15 000BTU HR 1 REFRIGERANT TON 12 000 BTU HR Page 41 8 8 PARTS LIST PART DESCRIPTION 800000 Caster 3 swivel 810000 Caster 3 rigid 895010 Coil Chas 3100 1527475 Condensing unit F3AHA101CFV 201 203 1 60 R 22 2169475 Filter drier C 0525 2971475 Expansion valve EVGE 1 CP100 4345900 CONTROLLER EWPC 902T Type J 4714350 Pump motor 1 2 HP 1725 RPM 230 1 60 3K090 6206498 Thermocouple Type J ungrounded SP 498 A4 B48 6214050 Procon pump CB2507XH AMP 1113 6648300 Relay GL7 2A TUBJ CB 230 volt 7550000 Pressure switch P7OMA 1 7591075 Rocker switch 2600A21E 7732200 Reservoir tank 06299 8213775 Transformer 44F3095 8828995 Bypass valve 5300A 1 2 Note this is a typical parts list Please obtain exact model and serial before contacting our parts department to assure an exact replacement part Page 42 VL Series Portable Chillers 0 25 to 1 5 Tons UGH020 0301 Conair has made the largest investment in customer support in the plastics industry Our service experts are available to help with any problem you might have installing and operating your equipment Your Conair sales representative also can help analyze the nature of your problem assuring that it did not result from misapplication or improper use To contact Customer Service personnel call PARTS amp SERVICE 800 458 1960 CON
5. 3 seconds The last entered setpoint will stay in memory VL Series Portable Chillers 0 25 to 1 5 Tons Page 15 Page 16 Arrow Down Arrow Output Status Light Set Button Press for less than 3 seconds to change setpoint Press for more than 4 seconds to access parameters UP used to increase the setpoint value as well as the parameter when in programming When held down for a few seconds the change rate accelerates DOWN used to decrease the setpoint value as well as the parameter when in programming When held down for a few seconds the change rate accelerates OUT status light of the output blinks when in setpoint display change mode or during programming DESCRIPTION OF PARAMETERS 1 D1 setpoint differential The switching differential hysteresis can be set with positive value make on rise or with negative value make on fall See parameter HC1 LS1 lower set This is the lower limit below which the user cannot change the setpoint normally set at the lowest value recommended for the sensor HS1 higher set Similar to LS1 however setting an upper limit for the setpoint od output delay This provides a delay selection for the outputs in applications where noise may cause brief erroneous signals from the sensor to the controller Factory set at 0 lower current input EWPC 902 R EWPC 902 P EWPC 902 T with current input only Read o
6. CALibration min C F 0 PSE Probe SElection Ni Pt Fe Cr th Fe HC1 Heating Cooling H C flag 1 relay Protection flag RO LF1 Led Function di in flag OF dp decimal Point on flag N hdd half digit display flag tAb tAble of parameter flag 3 Other parameters are accessed with the UP and DOWN button With the SET button the actual setting of each parameter is displayed To change a parameter setting push the SET plus the UP DOWN 4 The system will automatically return to its normal operating mode a few seconds after the programming procedure is completed or interrupted E ERROR ANNUNCIATION 1 Any sensor input defect will be displayed as follows in case of shorted sensor EEE in case of sensor break or sensor absence The EEE error message also appears the event of overrange of underrange of the system temperature 2 It is recommended to double check the sensor wiring before diagnosing a probe as defective 3 4 SHUT DOWN DISCONNECT SEQUENCE A PRECAUTIONS WARNINGS 1 The operator must precisely follow all shut down procedures outlined in this manual If the operator fails to do so an unsafe condition can develop resulting in damage to the unit or injury and or death to operating personnel B UNIT SHUT DOWN without system disconnect 1 To shut down the unit toggle off the rocker switch and disconne
7. over the phone consultation If the problem is beyond the scope of over the phone consultation and if the warranty status of the machine is valid Conair will contact the nearest authorized service contractor and provide authorization to conduct an on site inspection of the unit in order to determine the course of repair If the chiller is not covered by the warranty Conair will advise on the repair and recommend available service contractors Conair manufactures a complete line of heat transfer equipment It is of the utmost importance that Conair have the correct model number and serial number of the machine in question This will allow Conair to obtain the correct manufacturing records which will help the service department to properly troubleshoot the problem and obtain the proper replacement parts when they are required This information is stamped on the metal data tag that is attached to the machine The Conair service department must be notified prior to any repair or service of a warranty nature Warranty claims will not be honored without prior authorization 5 2 PERIODIC PREVENTATIVE MAINTENANCE Page 24 A Lubricate all motors Note that some motors are supplied with sealed bearings Tighten all wire terminals Clean and check motor starter and contactor contacts Check safety switch settings Clean condenser fins of dust and dirt Back flush evaporator Check glycol water solution ratio for operat
8. 0 4 1 60 4 1 60 4 1 60 4 1 60 4 1 Reservoir capacity gal liters 4 15 4 15 4 15 4 15 4 15 4 15 Dimensions 33 838 33 838 33 838 33 838 33 838 37 940 18 457 18 457 18 457 18 457 18 457 19 483 24 610 24 610 24 610 24 610 24 610 25 635 Pipe size NPT in Process to and from Condenser Voltages full load amps 115V 1 phase 60Hz 220V 1 phase 60Hz Refrigerant SPECIFICATION NOTES Ton capacity at 12 000 BTU ton 50 F leaving water temperature 115 F condensing temperature Capacities may be 5 as reserved by the compressor manufacturer Capacity multipliers are 50 F 1 00 40 F 0 80 30 F 0 60 20 F 0 40 t Hermetic reciprocating compressor t Consult pump curve for exact characteristics relating to pump performances 8 Unit weight crated for shipment No allowance for inrush Service disconnect by owner Full load amps must be used to size disconnects and supply conductors Consult factory for 50hz operation Specifications can change at any time Contact your Conair representative for the most current information Page 34 VL Series Portable Chillers 0 25 to 1 5 Tons UGH020 0301 8 2 OPERATION BELOW 48 F A A chiller typically operates with a setpoint of 50 F or higher However if setpoints between 20 48 F are required special precautions must be taken to prevent freezing and possible damage Attention must be
9. 0 X temperature difference X specific heat 12 000 ONS GPM water X AT 12 000 Gallon of Water 8 34 165 231 cubic inch 1337 cubic feet 3 785 liters 4 quarts 1 Pound of Water 1198 gallon 1 Cubic foot of Water 7 481 gallons 62 37 pounds METRIC CONVERSION TABLE 2546 5 BTU hr 745 7 watts 42 442 BTU min 1HP PSI X GPM 1199 1HP 7 Feet of Head GPM x Specific Gravity 2772 PSI 4331 X Feet of Head PSI Feet of Head 23 1 Foot of Head 4332 PSI Feet of Head PSIX2 3 Watts Amps X Volts single phase Amps X Volts X 1 73 three phase Volts Ohms X Amps Volts Watts Amps Volts 5 X Ohms Amps X Volts X 1 73 1KVA eee SEH hi 1000 three phase 1KVA single phase M KW X 300 Temperature Difference CFM _ Tons 10530 Temperature Difference KW _ CFM X Temperature Difference 3000 F 9 5 X C 32 C 5 9 X F 32 Volume of Cylinder Circumference of Circle Diameter of Circle TI XR XL Diameter of Circle Circumference X 3183 Area of Circle 7854 1 0353 oz 1 Foot 30 48 centimeter 454 116 102 28 35 1 Kilogram calorie 252 1 Millimeter inches X 25 4 1 Kilogram Lbs X 454 1 Square Centimeter 1 Square Inch VL Series Portable Chillers 0 25 to 1 5 Tons 155 square inch 6 452 sqaure centimeter TO CONVERT TO CONVERT FROM TO Mul
10. AIR 24 HOURS A DAY 7 DAYS A WEEK From outside the United States call 814 437 6861 You can commission Conair service personnel to provide on site service by contacting the Customer Service Department Standard rates include an on site hourly rate with a one day minimum plus expenses If you do have a problem please complete the following checklist before calling Conair O Make sure you have all model serial and parts list numbers for your particular equipment Service personnel will need this information to assist you Make sure power is supplied to the equipment O Make sure that all connectors and wires within and between control systems and related components have been installed correctly O Check the troubleshooting guide of this manual for a solution O Thoroughly examine the instruction manual s for associated equipment especially controls Each manual may have its own troubleshooting guide to help you O Check that the equipment has been operated as described in this manual O Check accompanying schematic drawings for information on special considerations IMS0002 0296 SERVICE INFORMATION WE RE HERE TO HELP How To CONTACT CUSTOMER SERVICE BEFORE YOu CALL Additional manuals and prints for your Conair equipment may be ordered through the Customer Service or Parts Departments for a nominal fee APPENDIX A 1 EQUIPMENT GUARANTEE PERFORMANCE WARRANTY WARRANTY LIMI
11. TATIONS APPENDIX A 2 Conair guarantees the machinery and equipment on this order for a period as defined in the quotation from date of shipment against defects in material and workmanship under the normal use and service for which it was recommended except for parts that are typically replaced after normal usage such as filters liner plates etc Conair s guarantee is limited to replacing at our option the part or parts determined by us to be defective after examination The customer assumes the cost of transportation of the part or parts to and from the factory Conair warrants that this equipment will perform at or above the ratings stated in specific quotations covering the equip ment or as detailed in engineering specifications provided the equipment is applied installed operated and maintained in the recommended manner as outlined in our quotation or specifi cations Should performance not meet warranted levels Conair at its discretion will exercise one of the following options Inspect the equipment and perform alterations or adjust ments to satisfy performance claims Charges for such inspections and corrections will be waived unless failure to meet warranty is due to misapplication improper installation poor maintenance practices or improper oper ation Replace the original equipment with other Conair equip ment that will meet original performance claims at no extra cost to the customer Refund
12. _ ELIWELL 902T lo 1 3 5 13 CONDENSING UNIT DUAL HIGH LOW 1 PRESSURESTAT 4 pul 11 _ 11 11 5 5 VL Series Portable Chillers 0 25 to 1 5 Tons UGH020 0301 Page 30 7 2 CIRCUIT SCHEMATIC ITEM DESCRIPTION Compressor Air cooled condenser Liquid receiver Filter drier Refrigerant sight glass Expansion valve Evaporator Pump To process connection From process connection Reservoir tank Refrigerant safety switch N O UGH020 0301 VL Series Portable Chillers 0 25 to 1 5 Tons Page 31 THIS PAGE INTENTIONALLY BLANK Page 32 VL Series Portable Chillers 0 25 to 1 5 Tons UGH020 0301 8 0 APPENDIX UGH020 0301 SPECIFICATIONS OPERATION BELOW 45 F WATER QUALITY CONTROL INHIBITED PROPYLENE GLYCOL CHILLER CAPACITY AND DERATE CHART PRESSURE TEMPERATURE CHART FOR R 22 REFRIGERANT ENGINEERING FORMULAS SPARE PARTS LIST VL Series Portable Chillers 0 25 to 1 5 Tons Page 33 8 1 SPECIFICATIONS VL Air cooled Portable Chillers 0 25 to 1 5 tons Performance characteristics Capacity tons 0 25 0 32 0 41 0 70 0 98 1 35 Compressor Hp kw t 0 25 0 19 0 33 0 25 0 5 0 37 0 75 0 56 1 0 75 1 5 1 1 Pump Hp kW 0 25 0 19 0 25 0 19 0 25 0 19 0 25 0 19 0 5 0 37 0 5 0 37 Chilled water flowt gpm lpm 0 6 2 3 0 8 3 0 0 9 3 4 1 7 6 4 2 4 9 1 3 6 13 6 Chilled water pressuret psi bar 60 4 1 6
13. ct the electrical supply Page 18 VL Series Portable Chillers 0 25 to 1 5 Tons UGH020 0301 40 TROUBLESHOOTING 4 1 UNIT WILL NOT START 4 2 PUMP WILL NOT START 4 3 COMPRESSOR WILL NOT START 4 4 UNIT SHUTS DOWN ON HIGH PRESSURE SWITCH 4 5 UNITS SHUTS DOWN ON LOW PRESSURE SWITCH UGH020 0301 VL Series Portable Chillers 0 25 to 1 5 Tons Page 19 4 1 4 2 4 3 4 4 4 5 Page 20 UNIT WILL NOT START A Blow fuse at power supply isolate open fuse and replace Double check fuse sizes against nameplate amperage Low voltage measure incoming voltage with meter voltage must be within 10 of nameplate voltage or warranty will be voided PUMP WILL NOT START Impeller bound or frozen shaft bearing in motor Open motor winding Internal overload tripped Loose wire connection or defective start capacitor On off circuit breaker tripped COMPRESSOR WILL NOT START A Safety switch open unsafe condition exists consult safety switch section in this manual Windings overheated over temperature switch on compressor tripped Circuit breaker tripped reset and check amperage Verify voltage is correct check for loose wire connection at motor Defective circuit breaker Bad or defective start capacitor UNIT SHUTS DOWN ON HIGH PRESSURE SWITCH A B Low air flow across condenser Check for dirty condenser fins Fan not operating Check for loose fan blade or open grounded
14. d maintenance of the unit Observe all warning and safety placards applied to the unit Failure to observe all warnings can result in serious injury or death to the operator and sever mechanical damage to the unit 1 4 CLEAN AIR ACT A The unit contains HCFC 22 chlorodifloromethane This is a class 2 substance Page 6 VL Series Portable Chillers 0 25 to 1 5 Tons UGH020 0301 Please be aware that effective July 1 1992 it is unlawful for person in the course of maintaining servicing repairing or disposing of refrigeration equipment to knowingly vent or otherwise dispose of any class 2 substance used as a refrigerant in the manner which permits such substance to enter the environment De minimis releases associated with good faith attempts to recapture reclaim or recycle such substance shall not be subject to the prohibition set forth in the preceding paragraph 1 5 MISCELLANEOUS A The purpose of the unit is to circulate temperature stabilized fluid through your process resulting in process temperature control B The ability of the unit to maintain process temperature control is significantly affected by the method of installation If the operator has any questions concerning the location operation of the unit please contact the Conair service at 800 458 1960 or 814 437 6861 Electrical Panel Reservoir Illuminated On switch 8 Controller Bypass Valv
15. e Thermocouple D Refrigerant Pump Ye Sight Glass gt Filter Dri Air Cooled Condenser SS oe ae Refrigerant Safety Switches a Power Liquid Receiver Caster UGH020 0301 VL Series Portable Chillers 0 25 to 1 5 Tons Page 7 THIS PAGE INTENTIONALLY BLANK Page 8 VL Series Portable Chillers 0 25 to 1 5 Tons UGH020 0301 20 INSTALLATION 2 1 GENERAL 2 2 TO AND FROM PROCESS CONNECTIONS 2 3 UNIT DRAIN 2 4 AIR COOLED CONDENSER 2 5 ELECTRICAL CONNECTION UGH020 0301 VL Series Portable Chillers 0 25 to 1 5 Tons Page 9 2 1 GENERAL A All process piping materials such as hose rigid piping valves or filters used in process water piping circuitry must be rated for 100 F minimum temperature and 100 PSI minimum pressure B All such materials must have the equivalent or larger diameter of the particular process connection that length of process water piping is connected to From process connection connect to water out on process manifold To process connection connect to water in on process manifold 2 2 TO AND FROM PROCESS CONNECTIONS A Connect the chiller s to process connection to the water in manifold on the mold or process B Connect the chiller s from process connection the water out manifold at the mold or process Process water piping circuitry should be designed to avoid excessive use of elbows and
16. es will leach out and form a gel like substance on the heat transfer surfaces and reduce cooling efficiency of the system These silicates have shown to significantly reduce the lifetime of pump seals E MAINTENANCE RESPONSIBILITY 1 A hygrometer should be used on a regular basis to determine the mixture strength according to freeze point The freeze point temperature should be 25 F below the lowest required setpoint see charts on page 35 and 37 Water will evaporate from the mixture and if you continue to add a premixed solution eventually you will have too much glycol It is necessary to add water or glycol to maintain proper freeze point temperature The device pictured is by far the most accurate and easy to use for maintaining and checking for proper glycol levels Contact Misco Products 1 800 358 1100 Model 7084VP Page 38 VL Series Portable Chillers 0 25 to 1 5 Tons UGH020 0301 8 5 CHILLER CAPACITY AND DERATE CHART Standard chiller rating is at 50 F For all other temperature settings UGH020 0301 output tonnage is altered as follows OUTPUT FULL TEMPERATURE AVAILABLE F CAPACITY 60 105 50 100 45 90 40 80 35 70 30 60 25 50 20 40 15 30 10 22 5 15 0 9 5 5 NOTES If operation of the chiller at less than 48 F is required an inhibited propylene glycol solution is required Consult factory for chiller opera
17. given to freeze protection water supply and safety adjustments B FREEZE PROTECTION 1 It is understood that untreated water freezes at 32 F Therefore an inhibited propylene glycol and water solution must be used in lieu of ordinary water Prescribed amounts are listed in figure 8 2A OPERATING ANTI FREEZE MIXTURE TEMPERATURE GLYCOL WATER 40 F 20 80 25 F 25 75 30 F 30 70 Figure 8 2A 2 On initial installation of the unit the water glycol solution should be premixed then added to the reservoir After the pump has been started water lines filled and air purged it may be necessary to add more water glycol solution to maintain the recommended reservoir level Note a hygrometer should be used on a regular basis to determine the mixture strength according to freeze point The freeze point temperature should be 25 below the lowest required setpoint Water will evaporate from the mixture and if you continue to add a premixed solution eventually you will have too much glycol It is necessary to add water or glycol to maintain proper freeze point temperature 3 PLEASE NOTE THAT A CHILLER IS NOT DESIGNED TO ACCOMMODATE AUTOMOTIVE TYPE ANTI FREEZE This is due to the fact that automotive type anti freeze contains silicates that adhere to heat transfer surfaces of the system preventing maximum heat transfer Also improper portions of inhibited propylene glycol to water inhibits effective heat transfer Consult the chi
18. ing temperature Check system for leaks VL Series Portable Chillers 0 25 to 1 5 Tons UGH020 0301 5 3 5 4 UGH020 0301 Refrigerant sight glass check for bubbles when compressor is operating at 100 Check the moisture indicator for a color other than green Clean unit SPECIAL MAINTENANCE A Any service of the refrigeration system must be accomplished by a certified refrigeration technician 1 Vacuum check compressor 2 Addition of compressor oil 3 Addition of refrigerant 4 Repair of a refrigerant leak 5 Adjustment of super heat 6 Changing of filter drier or drier core 7 Repair of a refrigeration solenoid 8 Valve plate replacement on compressor PUMP REPAIR A The positive displacement pump in the unit is not field serviceable To arrange for repair contact PROCON PUMPS 910 RIDGELY ROAD MURFEESBORO TN 37310 615 890 5710 VL Series Portable Chillers 0 25 to 1 5 Tons Page 25 THIS PAGE INTENTIONALLY BLANK Page 26 VL Series Portable Chillers 0 25 to 1 5 Tons UGH020 0301 6 0 COMPONENTS 61 WATER SYSTEM 6 2 REFRIGERATION SYSTEM UGH020 0301 VL Series Portable Chillers 0 25 to 1 5 Tons Page 27 6 1 WATER SYSTEM A MOTOR PUMP ASSEMBLY the motor pump assembly circulates chilled fluid to the process loop The pump assembly is built of brass to maintain water quality 6 2 REFRIGERATION SYSTEM A Page 28 COMPRESSOR hermetic compressors take low pressure low tem
19. ller s operating manual for specific details WATER SUPPLY 1 The automatic water supply if equipped restores the reservoir water level as needed However if untreated water is added to an water glycol solution dilution will occur decreasing the freeze protecting ability of the solution UGH020 0301 VL Series Portable Chillers 0 25 to 1 5 Tons Page 35 Therefore the water supply source must be disconnected and the connection capped The operator must monitor the water glycol level and manually make up to maintain proper reservoir level D SAFETY ADJUSTMENTS 1 To ensure safe and efficient operations at lower setpoints adjustments of the freezestat and low pressurestat factory settings are required Figure 8 2B lists the appropriate settings OPERATING LOW LOW FREEZESTAT TEMPERATURE CUT IN CUT OUT SETTING 48 F 55 40 38 F 40 F 50 35 30 F 35 F 45 30 25 F 30 F 40 25 20 F Figure 8 2B 2 The freezestat serves as the mainline defense against freezing in that it shuts down the chiller if the coolant temperature ever decreases to its setting For mechanical freezestats adjustments are made by removing the cover and rotating the selector dial with a screwdriver Electronic freezestats are adjusted through the setup parameters via the instrument control panel 3 The low pressurestat serves to protect the compressor from unsafe suction pressures Suction pressures decrease with lower ope
20. motor winding High ambient air temperature above 95 F Insufficient clear space around unit UNIT SHUTS DOWN ON LOW PRESSURE SWITCH A B Attempting to operate below 40 F Low refrigerant charge VL Series Portable Chillers 0 25 to 1 5 Tons UGH020 0301 Restriction to refrigerant flow in refrigeration circuit Poor heat transfer evaporator tank because 1 percentage of glycol to water is too high and 2 scaled tubes in evaporator tank chemically descale Low flow through evaporator tank due to 1 process flow restricted or 2 glycol foaming UGH020 0301 VL Series Portable Chillers 0 25 to 1 5 Tons Page 21 THIS PAGE INTENTIONALLY BLANK Page 22 VL Series Portable Chillers 0 25 to 1 5 Tons UGH020 0301 5 0 MAINTENANCE 5 1 WARRANTY SERVICE PROCEDURE 5 2 PERIODIC PREVENTATIVE MAINTENANCE 5 3 SPECIAL MAINTENANCE 5 4 PUMP REPAIR UGH020 0301 VL Series Portable Chillers 0 25 to 1 5 Tons Page 23 5 1 WARRANTY SERVICE PROCEDURE A In the event of a problem with a chiller that can not be resolved by normal troubleshooting procedures the customer is invited to consult the Conair service department for assistance The correct model number and serial number of the chiller must be available The service department will attempt to isolate the problem and advise repair procedures Often times with the customer s input and with the machine diagnostics problems can be determined with
21. ollow this segment to start up and operate the instrument controller This section includes information on automatic and manual venting setpoint selection and adjustment and feature explanations 3 4 Shut down procedure follow this segment to shut down the unit This segment includes information on system cool down shut down electrical power supply precautions and disconnection from system 3 2 START UP OPERATIONS PROCEDURE A SYSTEM FILL 1 The unit has an internal reservoir which must be filled and maintained for proper operation 2 Conair recommends the addition of 20 inhibited propylene glycol to the process fluid This should help prevent the process fluid from freezing and internal components from rusting A biocide must be added to the water to prevent organism growth in the chilled water system See water treatment section in section 8 of this manual for more information 3 Remove the top panel to access the reservoir Add fluid directly to the reservoir tank Please note when the pump is first started and after the process lines are filled and entrained air is purged additional fluid may be required to restore the reservoir to the correct level Reservoir Page 14 VL Series Portable Chillers 0 25 to 1 5 Tons UGH020 0301 3 3 UGH020 0301 OPERATIONS 1 2 Turn the thermostat to the highest setting Shift the illuminated toggle switch to the ON position The pump will begin operati
22. ons Note the reservoir level if it drops below 3 4 full add fluid Check the unit and process system for leaks Repair any that are discovered Adjust the setpoint thermostat as required for the process Note the compressor will start if the fluid temperature is above the selected setpoint temperature When the compressor starts listen for any knocking or other unusual noise Report any unusual noise to the Service department and discontinue operations Do not operate the unit without all sheet metal enclosure panels secured Process flow is adjusted according to the pump motor amperage This rating can be found on the pump motor data plate a With all process valves fully open and with the pump motor operating check amp draw with an amp meter and note findings b Compare amp draw with pump motor rating If excessive partially close the from process valve to adjust motor amps INSTRUMENT OPERATION A GENERAL DESCRIPTION A The EWPC 902 T R P controller is a new series of microprocessor based and fully programmable process controllers for single point applications The front keypad of this controller offers several alpha numeric menu prompts to configure the controller for each specific application FRONT KEYPAD 1 SET push to display the setpoint value The setpoint can be changed by using the up or down button The control will automatically switch back to normal operating mode within
23. or desires a GLYCOL WATER F C process temperature below 48 F Freeze protection is required so ice crystals do not form and cause severe damage to both the water and refrigeration system CHOOSING THE PROPER POINT MUST 25 F BELOW GLYCOL LOWEST SETPOINT 1 For getting the most efficiency from your system a propylene glycol such as DowFrost is a must DowFrost contains special corrosion inhibitors for low system maintenance and better transfer capabilities than normal glycols It also has a much longer fluid life up to 20 years in some Cases 2 SOURCES OF INHIBITED PROPYLENE GLYCOLS for a complete literature package material safety data sheets and purchasing information contact the following DOW CHEMICAL 1 800 447 4369 Canada 1 800 363 6250 Dowfrost inhibited propylene glycol MONSANTO CHEMICAL 1 800 459 2665 Monsanto FS inhibited propylene glycol UGH020 0301 VL Series Portable Chillers 0 25 to 1 5 Tons Page 37 USE OF PLAIN GLYCOL 1 Even through they do lower the freeze point plain glycols are even more corrosive than water The corrosion rate of plain ethylene glycol on iron for example is more than 2 5 times faster than plain water On steel it is 4 5 times faster AUTOMOTIVE BASED ANTIFREEZE 1 SHOULD NEVER BE USED Automotive antifreeze contains silicate based inhibitors which are compatible with automotive components In an industrial application the silicat
24. or lengths of pipe or hose If hose is the material of choice avoid tight twists or curls and excessive lengths D Valves and filters may be installed in the process water piping circuitry to facilitate service and maintenance provided that such devices maintain the full inside diameter of the process connection If installed all such devices must be open and clean during unit operation Page 10 VL Series Portable Chillers 0 25 to 1 5 Tons UGH020 0301 2 3 2 4 UGH020 0301 DRAIN CONNECTION A The unit is supplied as standard with a ProCon type pump In some cases it may be necessary to drain the unit This is done by removing the pump volute plug in the pump assembly Note that if chemical treatment of process fluid or additives are use drainage shall be done according to local codes It is important to note that drainage procedures must be done prior to shipment or outdoor storage or the unit If not freezing damage can _____ Motor Thermocouple Pump Drain plug AIR COOLED CONDENSER A Air cooled condenser require ambient air temperatures between 60 F and 95 F for efficient operation Operating above 95 F may result in elevated condensing pressures and eventual shut down on the high pressure safety switch Check with the Conair service department for more information on operating with ambient air temperatures above 95 F or below 60 F Air flow is generated by the motor driven fan
25. perature refrigerant gas and compress the gas into high pressure high temperature gas AIR COOLED CONDENSER the air cooled condenser removes BTUs from the compressor refrigerant gas The action causes the gas to condense into a liquid state still under high pressure Air flow across the condenser is achieved via a motor driven fan FILTER DRIER the filter drier removes contaminants and moisture from the liquid refrigerant LIQUID RECEIVER serves as a collection tank for high pressure liquid refrigerant to ensure total charge at all times REFRIGERANT SIGHT GLASS the refrigerant sight glass indicates refrigerant charge and moisture content Refrigerant charge is determined by a clear liquid flow Bubbles indicate low refrigerant Moisture content is indicated by the color of the element Element color is normally green If the color of the element is chartreuse or yellow the system has been contaminated with moisture In such case the filter drier must be replaced The replacement of the filter drier must be completed by a qualified refrigerant service technician EXPANSION VALVE the expansion valve throttles flow of refrigerant liquid into the evaporator and creates a pressure drop in the refrigerant system that allows the liquid refrigerant to boil off inside the evaporator EVAPORATOR the evaporator is a tube in tube heat exchanger where the refrigerant liquid is allowed to evaporate boil off to absorb heat BTU f
26. rating setpoints To prevent short cycling of the compressor the low pressurestat must be adjusted to accommodate the lower setpoint Adjustments to the low pressurestat are made by rotating the adjusting screws on top of the control and observing the movement of the pointers in the control window until the prescribed setting is determined E PRECAUTIONS 1 At any setpoint the possibility of freezing exists and it is the operator s responsibility to take necessary action to prevent freezing at all times Page 36 VL Series Portable Chillers 0 25 to 1 5 Tons UGH020 0301 8 3 WATER QUALITY CONTROL A Lack of as well as improper water treatment can damage the chilling unit The services of a competent water treatment specialist should be obtained and their recommendations followed It is the equipment owner s responsibility to prevent damage from foreign material or inadequate water treatment B The two main things to consider for water treatment in chillers are corrosion and organism growth Proper chemical treatment can control PH levels and algae growth An alternative to chemical treatment is the addition of 20 inhibited propylene glycol to the water This will help prevent organism growth and coat the heat transfer surfaces with corrosion inhibitor 8 4 INHIBITED PROPYLENE GLYCOL FREEZING POINTS FOR WATER PROPYLENE GLYCOL SOLUTIONS A The use of a water glycol mixture is needed when PERCENTAGE OF FREEZE POINT the operat
27. rom the process fluid As the heat is absorbed the process fluid is chilled HIGH LOW PRESSURESTATS the high low pressurestats protect the refrigeration system from unsafe operating levels The high pressure switch is factory set to open at 325 psi and protects the refrigeration components and personnel from potential damage of injury from excessive high pressure The high pressure safety must not be altered in the field for any reason The low pressure switch is factory set to open at 58 psi and to close at 63 psi The low pressure switch protects the chillers from possible damage due to low operating pressure The low pressure switch is field adjustable for setpoints below 48 F VL Series Portable Chillers 0 25 to 1 5 Tons UGH020 0301 7 0 RELATED DRAWINGS 7 1 ELECTRICAL DRAWING TYPICAL 7 2 CIRCUIT SCHEMATIC UGH020 0301 VL Series Portable Chillers 0 25 to 1 5 Tons Page 29 7 1 ELECTRICAL DRAWING TYPICAL UNIT ON OFF gt 6 6 oo 4 POWER ENTRY 230 1 60 GREEN GREEN E gt 5 al 230 1 60 PRIMARY 24 2 2 SECONDARY 4 4 7 BLU 5 BLU 1 6 a 8 5 0 1 9 PUMP a TYPE J 7 10 THERMOCOUPLE 3 4 gt 7 8 9 10 ee
28. t has an air cooled refrigerant condenser For air cooled condensers a motor driven fan generates air flow through the condenser to remove heat from the refrigerant system The air cooled condenser on the unit will discharge a maximum of 15 000 BTUs per hour per ton of cooling The unit must have a minimum entering air temperature of 60 F and a maximum entering air temperature of 95 F for efficient operation The unit must have minimum of two feet clearance at the air intake and six feet at the exhaust air discharge E If the operator has any questions concerning the location and operation of the unit contact the Conair service department at 800 458 1960 1 2 EFFICIENCY A Long term efficiency of operation is largely determined by proper maintenance of the mechanical parts of the unit and the water quality Conair recommends filtering where required to prevent solids from plugging critical parts pumps heaters seals for example Conair highly recommends the services of a competent water treatment specialist be obtained and his recommendations followed Conair accepts no responsibility for inefficient operation or damage caused by foreign materials or failure to use adequate water treatment 1 3 SAFETY A It is important to become thoroughly familiar with this manual and the operating characteristics of the unit B It is the owner s responsibility to assure proper operator training installation operation an
29. t is changed from without decimal point to with decimal point all parameter values expressed in degrees will automatically be divided by 10 including the setpoint c The decimal point selection is not available on models for thermocouple input hdd half digit display The right most digit can be set to read out in 0 or 5 only or in all 10 digits hdd e g 070 071 072 etc if without decimal point or 70 0 70 1 70 2 etc if with decimal point hdd y e g 070 075 080 etc if without decimal point or 70 0 70 5 80 0 etc if with decimal point Useful when measuring values varying rapidly e g R H tAb tAble of parameters This shows the configuration of the parameters as set in the factory can not be modified for factory identification and diagnostic purposes only PARAMETERS DEFAULTS Programming is easily accessed by holding the SET button down for more than 4 seconds The first parameter is displayed while the status light Led out remains blinking during the programming period VL Series Portable Chillers 0 25 to 1 5 Tons Page 17 DEFAULT SETTING STANDARD MODLES PARAMETER DECRIPTION RANGE UNIT FACTORY d1 differential min max C F 4 151 Lower Set min max C F 40 HS1 Higher Set min max C F 70 od output delay min max seconds 60 Lei Low current input min max various 0 High current input min various 0 CAL
30. the invoiced cost to the customer Credit is sub ject to prior notice by the customer at which time a Return Goods Authorization Number RGA will be issued by Conair s Service Department Returned equip ment must be well crated and in proper operating condi tion including all parts Returns must be prepaid Purchaser must notify Conair in writing of any claim and pro vide a customer receipt and other evidence that a claim is being made Except for the Equipment Guarantee and Performance Warranty stated above Conair disclaims all other warranties with respect to the equipment express or implied arising by operation of law course of dealing usage of trade or oth erwise including but not limited to the implied warranties of merchantability and fitness for a particular purpose WARRANTY INFORMATION IMS0003 0796
31. tion below 20 F Ambient conditions affect air cooled chiller operation and capacity Standard rating is at 95 F entering air temperature For ambient air conditions greater than 95 F chiller derating will occur For ambient temperatures of 95 105 F select the next larger capacity chiller For ambient temperatures over 105 F consult factory These ranges require special options VL Series Portable Chillers 0 25 to 1 5 Tons Page 39 8 6 PRESSURE TEMPERATURE CHART FOR R 22 REFRIGERANT SATURATED TEMPERATURE FREON PRESSURE Po 68 p 76 50 84 55 93 _____ __ __ 100 G59F 112 ne 122 75 F eee 132 144 BSP 156 168 182 100 196 THESE PRESSURE TEMPERATURE RELATIONSHIPS ARE IN AN AT REST SATURATED CONDITION FOR EXAMPLE IF THE UNIT HAS BEEN IN A WAREHOUSE AT 40 AND IS BROUGHT INTO A ROOM WHERE IT IS 80 IT MAY TAKE A COUPLE OF HOURS FOR THE UNIT TO WARM UP AND THE PRESSURE TO RISE TO THE SURROUNDING AMBIENT CONDITIONS Page 40 VL Series Portable Chillers 0 25 to 1 5 Tons UGH020 0301 8 7 UGH020 0301 USEFUL ENGINEERING FORMULAS 1 ton 12 000 btu BTU Material Ibs X material s specific heat X temperature difference 1BTU 293 watts 1watt 3 42 KW 1000 watts 3420 BTUs BTU hr GPM for water cooled condensers ONS GPM water X 8 34 X 6
32. tiply by FROM TO Multiply by UNIT VOLUME POWER US GPM _liters min 3 785 FT LB SEC watts 1 356 US GPM 2271 BTUH 3420 CFM liters min 28 317 Boiler HP 33475 CFM cum hr 1 6992 HP BTUH 2545 UNIT WEIGHT HP kw 7457 Lbs sqin grsq cm 70 31 Lbs sqin 6 894 BTU kg cal 252 Lbs sqin kg sqem 07031 BTU LB kg cal 5556 Lbs cuin gr cucm 27 68 BTU SQ gr cal sq 2713 LENGTH BTU CUFT kg cal cum 8 899 2 540 Inches cm 3048 WEIGHT Feet meters Grains 064 9144 grams 0648 Yards meters 1 609 unces grams 28 350 Miles km Pounds kg 4536 VOLUME US tons Ig 907 2 Cu inches 16 387 US tons tonnes 9072 Cu inches liters 01639 t 101 Cu feet cu meters 02832 9 ele Cufeet liters 28 317 AREA 259 Cu years meters 7646 Sqinches 6 45 Flounces 29 57 Sqyears 8361 US gal liters 3 785 Sq miles sq km 2 590 Auoirdupois pounds and ounces TEMPERATURE F 0 17 8 35 17 5 15 40 44 F to C F 30 55 10 12 2 45 72 15 9 4 50 10 0 oF _ 0 5 00 60 1 8 22 30 11 60 15 6 ABBREVIATIONS EQUIVALENTS amp FORMULAS 1 GALLON 8 33 Ibs water 1 CUBIC FOOT 7 48 gallons TOWER CELL EVAPORATION RATE 2 gal per ton per hour PSI Pounds Per Square Inch GPM Gallons Per Minute EWT Entering Water Temperature LWT Leaving Water Temperature BTU British Thermal Unit
33. us INSTALLATION 2 1 General 2 2 To and From process connections 2 3 Unit drain 2 4 Air cooled condenser 2 5 Electrical connection OPERATIONS SEQUENCE 3 1 General 3 2 Start up operations procedure 3 3 Instrument operation 3 4 Shut down disconnect sequence TROUBLESHOOTING 4 1 Unit will not start 4 2 Pump will not start 4 3 Compressor will not start 4 4 Unit shuts down on high pressure switch 4 5 Unit shuts down on low pressure switch MAINTENANCE 5 1 Warranty service procedure 5 2 Periodic preventative maintenance 5 3 Special maintenance 5 4 Pump repair COMPONENTS 6 1 Water system 6 2 Refrigeration system RELATED DRAWINGS 7 1 Electrical typical 7 2 Circuit schematic APPENDIX 8 1 Specifications 8 2 Operations below 48 F 8 3 Water quality control 8 4 Inhibited propylene glycol 8 5 Chiller capacity and derate chart 8 6 Pressure temperature chart for R 22 8 7 Engineering formulas 8 8 Spare parts list VL Series Portable Chillers 0 25 to 1 5 Tons Page 3 THIS PAGE INTENTIONALLY BLANK Page 4 VL Series Portable Chillers 0 25 to 1 5 Tons UGH020 0301 1 0 GENERAL 1 1 UNIT LOCATION 1 2 EFFICIENCY 1 3 SAFETY 1 4 CLEAN AIR ACT 1 5 MISCELLANEOUS UGH020 0301 VL Series Portable Chillers 0 25 to 1 5 Tons Page 5 1 1 UNIT LOCATION A The unit is designed for indoor use only For most efficient operation locate the chiller in a clean dry and well ventilated environment B The uni
34. ut corresponding to 4 mA input signal factory set at 20 R H for EWPC 902 R Hci high current input for EWPC 902 R EWPC 902 P and EWPC 902 T with current input only Read out corresponding to 20 mA input signal factory set at 100 R H for EWPC 902 R CAL CALibration This offers an adjustment up or down of the read out if needed Factory set at 0 VL Series Portable Chillers 0 25 to 1 5 Tons UGH020 0301 UGH020 0301 10 11 12 13 14 15 PSE Probe SElection Input type for RTD or Thermocouples only RTD models Ni Ni100 Pt Pt100 T C models FE Cr TeK rh 5 HC1 Heating Cooling Relay switch function H heating humidification reverse action C cooling dehumidification direct action rP1 relay Protection 1 Determines the status of the relay in case of sensor defect Factory set at ro ro relay open rc relay closed LF1 Led Function 1 Determines whether the status light in ON or OFF in relation to output 1 di direct light ON when output 1 is energized in reverse light OFF when output 1 is energized dP decimal Point Choose whether the resolution is required with or without decimal point oF without decimal point on with decimal point Notes a the decimal point of models with current or voltage input is shifted the actual value of parameters and Hci must be multiplied by 10 b On all versions if a uni
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