WARNING - Reliance on this Manual Could Result in Severe Bodily Injury or Death! This manual is out-of-date and is provided only for its technical information, data and capacities. Portions of this manual detailing procedures or precautions in the operation, inspection, maintenance and repair of the product forming the subject matter of this manual may be inadequate, inaccurate, and/or incomplete and cannot be used, followed, or relied upon. Contact Conair at info@conairgroup.
Please record your equipment’s model and serial number(s) and the date you received it in the spaces provided. It’s a good idea to record the model and serial number(s) of your equipment and the date you received it in the User Guide. Our service department uses this information, along with the manual number, to provide help for the specific equipment you installed. Please keep this User Guide and all manuals, engineering prints and parts lists together for documentation of your equipment.
INTRODUCTION . . . . . . . . . . . . . . . . . . .1-1 Purpose of the User Guide . . . . . . . . . . . . . . . . . . . . . . . . .1-2 How the guide is organized . . . . . . . . . . . . . . . . . . . . . . . .1-2 Your responsibility as a user . . . . . . . . . . . . . . . . . . . . . . .1-2 ATTENTION: Read this so no one gets hurt . . . . . . . . . . .1-3 TABLE OF CONTENTS DESCRIPTION . . . . . . . . . . . . . . . . . . . .2-1 What is the microKool chiller? . . . . . . . . . . . . . . . . . . . . . .
TABLE OF CONTENTS MAINTENANCE . . . . . . . . . . . . . . .(continued) Performing System Tests . . . . . . . . . . . . . . . . . . . . . . . . . .5-7 The Key/Display Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-8 Input Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-9 Output Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-10 Disabling and Enabling Outputs . . . . . . . . . . . . . . . . . . . .
INTRODUCTION ● Purpose of the User Guide . . . .1-2 ● How the guide is organized . . . .1-2 ● Your responsibilities as a user .1-2 ● ATTENTION: Read this so no one gets hurt . . . . . . . . . . .
PURPOSE OF THE USER GUIDE HOW THE GUIDE IS ORGANIZED This User Guide describes the Conair microKool water-cooled and air-cooled portable chillers and explains step-by-step how to install, operate, maintain and repair this equipment. Before installing this product, please take a few moments to read the User Guide and review the diagrams and safety information in the instruction packet. You also should review manuals covering associated equipment in your system.
We design equipment with the user’s safety in mind. You can avoid the potential hazards identified on this machine by following the procedures outlined below and elsewhere in the User Guide. ATTENTION: READ THIS SO NO ONE GETS HURT WARNING: Improper installation, operation or servicing may result in equipment damage or personal injury.
DESCRIPTION ● What is the microKool chiller? .2-2 ● Typical applications . . . . . . . . . .2-2 ● How it works: Water-cooled models . . . . . . . .2-3 ● How it works: Air-cooled models . . . . . . . . . . .2-4 ● Features . . . . . . . . . . . . . . . . . . .2-5 ● Specifications: Water-cooled . . .2-6 ● Specifications: Air-cooled . . . . .2-7 ● Freeze protection requirements . . . . . . . . . . . . . .
WHAT IS THE MICROKOOL CHILLER? The microKool portable chillers are designed to provide chilled water for industrial applications requiring 24-hour-aday performance. Operation of air-cooled and water-cooled units differ only in the medium used to remove heat from the refrigerant in the condensers. Water-cooled models use 85° F (29° C) cooling tower water, and are equipped with high efficiency tube-in-tube condensers with water regulating valves.
Water-cooled models use tube-in-tube heat exchangers to condense the hot, compressed, refrigerant gas from the compressor to a cool liquid. The cool liquid refrigerant passes through a filter/dryer, which protects the system from moisture or other contaminants. An in-line sight glass gives a visual indication of proper refrigerant charge and any dangerous moisture present in the system.
HOW IT WORKS: AIR COOLED Air-cooled models use aluminum-finned, copper tube condensers to condense the hot, compressed, refrigerant gas from the compressor to a cool liquid. The cool liquid refrigerant passes through a filter/dryer, which protects the system from moisture or other contaminants. An in-line sight glass gives a visual indication of proper refrigerant charge and any dangerous moisture present in the system.
FEATURES High Efficiency Compressors All microKool chillers are equipped with quiet Copeland hermetically sealed compressors. Hotgas bypass capacity control is standard, permitting efficient operation with cooling loads as low as 25% of rated chiller capacities. Control Extension Controls can be extended approximately 11 inches from the control base. Molded Plastic Reservoirs Large,thick-walled, insulated polyethylene reservoirs provide corrosion-free operation.
SPECIFICATIONS: MPW (WATER COOLED) Pressure (psi) 60 HZ PUMP PERFORMANCE CURVES Flow Rate (gpm) MODEL Performance characteristics Capacity {tons} * Compressor Hp {kW} Pump Hp {kW} † Chilled water flow gpm {l/min} ‡ Chilled water pressure psi {bar} § Reservoir capacity gal (l) Condenser water flow gpm {l/min} Dimensions inches {mm} A - Height ** B - Depth C - Width Weight lb {kg} Shipping weight Installed weight Utility requirements Water connections NPT (female) inches Process and condenser water inches
SPECIFICATIONS: MPA (AIR COOLED) Pressure (psi) 60 HZ PUMP PERFORMANCE CURVES Flow Rate (gpm) MODEL Performance characteristics Capacity {tons} * Compressor Hp {kW} Pump Hp (kW)† Chilled water flow gpm {l/min}‡ Chilled water pressure psi {bar}§ Reservoir capacity gal {l} Number of condenser fans Condenser fan power Hp {kW} Condenser air flow ft3/min {l/min} Dimensions inches {mm} A - Height ** B - Depth C - Width Weight lb {kg} Shipping weight Installed weight Utility Requirements Water connections NPT (
to Process Set Temperature, degrees F FREEZE PROTECTION REQUIREMENTS Freeze Protection Requirements by Unit Set Temperature 60 50 40 30 20 10 0 -10 -20 -30 -40 -50 -60 Temperature, degrees F 0 DESCRIPTION 100 Freezing Points of Aqueous Ethylene Glycol Solutions 40 30 20 10 0 -10 -20 -30 -40 -50 -60 -70 -80 0 2-8 20 40 60 80 Ethylene Glycol, % by weight 20 40 60 80 Ethylene Glycol, % by weight microKool Portable Chillers 100 UGH004/0999
INSTALLATION ● Unpacking the boxes . . . . . . . . .3-2 ● Preparing for installation . . . . . .3-3 ● Connecting the water supply . .3-4 ● Connecting the main power . . .3-5 ● Testing the installation . . . . . . . .3-6 ● Entering setpoint deviation parameters . . . . . . . .3-7 ● Initial setup . . . . . . . . . . . . . . . .3-8 ● Changing temperature units . . .3-9 ● Enabling and disabling passcode protection . . . . . . .3-10 ● Selecting the temperature control point (PC-2 Control) . . . . .
UNPACKING THE BOXES 3-2 INSTALLATION MicroKool Portable Chillers come fully assembled. 1 Carefully remove the chiller and components from their shipping containers, and set upright. 2 Remove all packing material, protective paper, tape, and plastic. Check inside the electrical enclosure and behind the side panels for accessories or hardware that may have been placed there for shipping.
The microKool chiller is easy to install, if you plan the location and prepare the area properly. 1 Position the chiller as close to the process machine as possible. PREPARING FOR INSTALLATION Chiller Process machine Alternate locations 2 Make sure the installation area provides: ❒ A three-phase power source supplying the correct current for your chiller model.
CONNECTING PROCESS AND WATER SUPPLY LINES The chiller process inlets and outlets must be connected to the plumbing that will circulate the temperature-controlled water or fluid through the process. Cooling water inlets and outlets are connected to the cooling water supply. 1 2 Tools for installation: ❒ Pipe wrench large enough for a 2-inch pipe ❒ Premium quality Teflon thread sealant Remove the shipping pipe plug from the female connections on the back of the chiller.
WARNING: Electrical shock hazard This equipment is powered by three-phase main voltage. Always disconnect and lock out the main power source before performing any work involving electrical connections. All wiring, disconnects and fusing should conform to your region’s electrical codes and should be installed only by qualified personnel. Before beginning, note the electrical specifications on the nameplate mounted to the side of the unit.
TESTING THE INSTALLATION WARNING: Only qualified personnel should perform this procedure. Parts of this test require opening the unit while it is energized. Only qualified personnel who have been trained in the use of electrical testing devices and in avoiding the safety hazards involved in safely troubleshooting this type of equipment should perform this test procedure. 1 Turn on the condenser water supply (MPW units) and check for leaks.
You can establish a normal operating range around the process temperature setpoint using the high and low deviation parameters. If the process temperature exceeds the high deviation limit, or falls below the low deviation limit for longer than 15 minutes, the chiller will alert you to the unacceptable temperature variation with an alarm light. These temperature deviation limits will adjust automatically relative to the process temperature setpoint.
INITIAL SETUP WARNING: Electric shock hazard This equipment is powered by high voltage. Always disconnect and lock out the main power source before opening the unit or the electrical enclosure to modify factory settings. Failure to disconnect and lock out the main power source can result in severe personal injury. The factory-set parameters and operating modes will satisfy most applications. But you can change some settings and enable or disable features as needed.
WARNING: Electric shock hazard This equipment is powered by high voltage. Always disconnect and lock out the main power source before opening the unit or the electrical enclosure to modify factory settings. Failure to disconnect and lock out the main power source can result in severe personal injury. CHANGING TEMPERATURE UNITS The temperature units are factory-set as degrees Celsius or degrees Fahrenheit, as specified when the unit was ordered.
ENABLING AND DISABLING PASSCODE PROTECTION WARNING: Electric shock hazard This equipment is powered by high voltage. Always disconnect and lock out the main power source before opening the unit or the electrical enclosure to modify factory settings. Failure to disconnect and lock out the main power source can result in severe personal injury. The PC-1 and PC-2 controls provide the ability to protect system parameters from unauthorized changes during normal operating mode.
ENABLING AND DISABLING PASSCODE PROTECTION 7 Press the RUN button to save the passcode. ◆ The control will display “Pr OFF” to prompt you to remove power to the unit. IMPORTANT: If RUN is not pressed, the new passcode will not be saved. 8 9 Turn off power to the unit. Disconnect and lock out the main power supply. Open the electrical enclosure. 8 7 6 5 4 3 2 1 10 Set dip switch 3 to OFF. the electrical enclosure and restore 11 Close power to the unit.
SELECTING THE TEMPERATURE CONTROL POINT (PC-2 WARNING: Electric shock hazard This equipment is powered by high voltage. Always disconnect and lock out the main power source before opening the unit or the electrical enclosure to modify factory settings. Failure to disconnect and lock out the main power source can result in severe personal injury.
SELECTING THE TEMPERATURE CONTROL POINT (PC-2 8 CONTROL ONLY) Press the RUN button to save the control point. ◆ The control will display “Pr OFF” to prompt you to remove power to the unit. IMPORTANT: If RUN is not pressed, the new control point source will not be saved. 9 10 Turn off power to the unit. Disconnect and lock out the main power supply. Open the electrical enclosure. 8 7 6 5 4 3 2 1 11 Set dip switch 5 to OFF. 12 Close the electrical enclosure and restore power to the unit.
INSTALLING THE AUTO START FEATURE WARNING: Electric shock hazard This equipment is powered by high voltage. Always disconnect and lock out the main power source before opening the unit or the electrical enclosure to modify factory settings. Failure to disconnect and lock out the main power source can result in severe personal injury.
6 Set dip switch 4 to the ON position. 7 Close the electrical enclosure and restore power to the unit. 8 7 6 5 4 3 2 1 INSTALLING THE AUTO START FEATURE (PC-2 CONTROL ONLY) When Auto Start is enabled: ◆ The Auto Start indicator light flashes to indicate that the Chiller can start at any time. The chiller will start whenever the remote switching or timing device sends a signal to start processing. ◆ The Auto Start indicator light is on whenever the chiller is under the control of the remote device.
ACTIVATING SPI COMMUNICATION MicroKool portable chillers provide SPI compatible support for RS-485 serial communications with a host machine. You can use SPI communication to change or monitor the: ● Process temperature setpoint ● High and low temperature deviation alarms ● Process status (run and alarm conditions) ● Machine 1 status ● Machine 2 status ● Actual temperature to process ● Actual temperature from process NOTE: To disable SPI, use the setpoint ▲ or ▼ arrow to select Address.
OPERATION ● PC-1 control features . . . . . . . . .4-2 ● PC-2 control features . . . . . . . . .4-3 ● Positioning the control panel . .4-4 ● Entering a passcode . . . . . . . . .4-5 ● Starting the chiller . . . . . . . . . . .4-6 ● Stopping the chiller . . . . . . . . . .4-7 ● Using the PC-2 pumpdown feature . . . . . . . . . . . . . . . . . . .4-9 ● Performing an Auto Tune . . . . .
PC-1 CONTROL FEATURES All normal operating functions can be controlled from the microKool PC-1 control panel. Setpoint display Run/Stop Actual values display The Setpoint display shows the setpoints entered for fluid temperature, high and low temperature deviation alarms, the SPI baud rate, and the SPI address. Press the RUN button to start normal operation. Press STOP to stop the unit. The green window displays the temperature at the middle of the process.
All normal operating functions can be controlled from the microKool PC-2 control panel, including the optional pumpdown feature. PC-2 CONTROL FEATURES Setpoint display Run/Stop Actual values display The Setpoint display shows the setpoints entered for fluid temperature, high and low temperature deviation alarms, the SPI baud rate, and the SPI address. Press the RUN button to start normal operation. Press STOP to stop the unit. The green window displays the temperature at the middle of the process.
POSITIONING THE CONTROL PANEL CAUTION: Improper use of the swiveling control panel can damage the unit. ● Do not rotate the control panel 360 degrees. This will twist and possibly damage the control wiring and connections to the motherboard in the electrical enclosure. ● Do not use the control panel handles or control cables to move the chiller. The handles are designed only for orientation of the control panel. ● Do not mount the detachable PC-2 control panel to a hot surface.
ENTERING A PASSCODE PC-1 and PC-2 controls have a security feature that prevents accidental or unauthorized changes to the setpoint temperature, high and low deviation limits, SPI address, and baud rate. If passcode protection is enabled, you must enter the correct passcode to change these parameters. To enter the passcode: 1 Press and hold the Setpoint Select button for 5 seconds. The control will display 1 PaS to indicate a passcode is needed.
STARTING THE CHILLER Before starting the chiller, verify that the system has been installed correctly for your application. See the INSTALLATION section. If Passcode Protection has been enabled, you must enter the correct passcode before you can change or enter any of the operating parameters, including the setpoint. 1 This allows time for crankcase heater to evaporate liquid refrigerant migrating in the compressor. When power is turned on: ◆ The compressor crankcase heater turns on.
WARNING: Electrical shock hazard Before attempting maintenance of any kind on the chiller, you must stop the unit; disconnect and lockout the main power supply. STOPPING THE CHILLER You must shut down the chiller whenever you: ● Change water or process hookups. ● Shut down the process machine. ● Run the unit’s diagnostic tests. ● Perform routine or preventative maintenance. ● See an alarm condition that requires troubleshooting. ● Relocate, ship or store the unit.
PERFORMING AUTO TUNE AN WARNING: Electric shock hazard This equipment is powered by high voltage. Always disconnect and lock out the main power source before opening the unit or the electrical enclosure to modify factory settings. Failure to disconnect and lock out the main power source can result in severe personal injury.
PERFORMING AUTO TUNE 5 AN Press Run and (the Setpoint Select button) simultaneously to begin the Auto Tune. The Actual display will flash “At” and the current process temperature to indicate that an Auto Tune is underway. If Auto Tune is successful, the controller automatically starts controlling using the new PID parameters. If you press the STOP button or a fault occurs during the Auto Tune, the control enters stop mode and Auto Tuning immediately terminates. The actual display stops flashing “At.
MAINTENANCE ● Maintenance schedule . . . . . . . .5-2 ● Cleaning evaporators . . . . . . . .5-4 ● Cleaning condensers . . . . . . . .5-4 ● Filling the tank . . . . . . . . . . . . .5-5 ● Checking refrigerant charge . . .5-6 ● Performing system tests . . . . . .5-7 ● Key/Display Test . . . . . . . . . . . . .5-8 ● Input Test . . . . . . . . . . . . . . . . . .5-9 ● Output Test . . . . . . . . . . . . . . . .5-10 ● Disabling or enabling output monitors . . . . . . . . . .
PREVENTATIVE MAINTENANCE SCHEDULE To maintain the best performance, we recommend the following maintenance schedule. ● Whenever process variables change ❒ Perform an Auto Tune. The Auto Tune ensures that the control continues to obtain good approximations of the PID constants used to compensate for the thermal lag of the system..
● Quarterly (every 3 months) ❒ Inspect power cords, wires and electrical connections. Check for loose or frayed wires, burned contacts, and signs of overheated wires. Check exterior power cords to the main power source and from the electrical box to the pump and heating elements. Check the ground wire and thermocouple connections. Replace any wire that appears damaged or has worn or cracked insulation.
CLEANING EVAPORATORS Minerals and other water system contaminants produce deposits, scales, slime, or algae on the heat-transfer surfaces exposed to water. Fouled surfaces decrease cooling capacity. We recommend that you consult a water treatment specialist to develop a treatment program that will minimize fouling.
The process fluid, which can be water or a glycol mixture, is held in a tank inside the unit. This tank should be kept at least three-quarters full of the process fluid. You can check the fluid level in the tank using the sight glass on the back of the chiller. 1 2 REFILLING THE TANK Tank fill port To fill the reservoir: Locate the fill port at the back of the chiller. Refill the tank. Monitor Tank level the level using the sight sight glass glass on the back of the unit.
CHECKING REFRIGERANT CHARGE All chillers are fully charged with refrigerant at the factory. Your chiller mode’s nameplate identifies the type and amount of total refrigerant charge required. 1 While the unit is running, check the refrigerant charge through the sight glass located between the evaporator and the condenser. Use a flashlight to look at the liquid-line sight glass. ◆ Under full-load conditions, the sight glass should be clear.
The microKool portable chillers provide a Test Mode that tests displays and keys on the control panel, as well as inputs and outputs. The Test Mode also allows calibration of the supply and return line thermocouples. PERFORMING SYSTEM TESTS System tests and calibration should be performed annually. To enable Test Mode: 1 Press 2 Disconnect and lock out main power to the unit, then open the electrical enclosure. 3 Set dip switches 3 and 5 to OFF. 4 5 Set dip switch 6 to ON.
KEY/DISPLAY TEST The Key/Display Test verifies the function of displays, LEDs and buttons on the control panel. 1 Enable Test Mode. 2 3 Press any key. If necessary, index to the Key/Display menu. Press and hold the Setpoint key for 3 seconds to index to each test menu until the controller displays “dSP”. 4 5 Press any key to clear all displays. 6 Exit the test and enter the next test. Repeatedly press any key to test displays.
The Input Test verifies the function of inputs available on the various models of the microKool chiller. Not all inputs are used on all models. The performance evaluation of the inputs is based on the voltage sensing device (VSD). 1 Connect all inputs to the system. 2 3 Press any key to display the first test menus. INPUT TEST Select the Input Test menu. Press and hold the Setpoint key for 3 seconds to index to each test menu until the controller displays “InP”.
OUTPUT TEST The Output Test verifies the function of outputs available on the various models of microKool chillers. Not all outputs are used on all models. The performance evaluation of the inputs is based on the output monitors (OM). 1 Connect all outputs to the system. IMPORTANT: Testing each output requires the firing of the associated solid state relay. Make sure an output device is connected to the controller, otherwise the test result will be erroneous. 2 3 4 Enable Test Mode.
All output monitors on the microKool chiller can be enabled or disabled permanently through the OM Enable/Disable Menu in Test Mode. You need to use this feature if you have replaced the motherboard, or if dip switches 7 and 8 have been changed erroneously. This will enable any required output monitors that were disabled and give fuse failures. 1 2 Enable Test Mode. 3 Select the OM Enable/Disable menu. DISABLING ENABLING OUTPUT MONITORS OR Press any key to display the first test menus.
CALIBRATING TEMPERATURE SENSORS Special Tools Needed: ❒ thermocouple calibrator The microKool chillers use thermocouples to sense the temperature in the return and supply process lines. These thermocouples should be calibrated annually, or when a new thermocouple is installed, to ensure correct operation. The chiller’s Calibration Mode provides zero and span calibration of both the supply and return line thermocouples. You access the Calibration Mode while in Test Mode. 1 Enable Test Mode.
6 Press the up ▲ key to begin calibrating. The controller displays the name of the current calibration (examples: 32 SC.L; 32 rC.L; 510 SC.H; or 510 rC.H). 7 CALIBRATING TEMPERATURE SENSORS Wait until the control displays “don” or “bad.” A “don” message in the Setpoint display indicates the calibration was successful. A “bad” message in the Setpoint display indicates a bad calibration.
LOGGING OPERATING HOURS You can see the total numbers of operation by accessing the Total Operating Hours Log in Test Mode. 1 2 Enable Test Mode. 3 Index through test menus to the operating log. Press any key to display the first test menus. Press and hold the Setpoint key for 3 seconds to index to each test menu until the Actual display indicates “Log”. The Setpoint display indicates the total number of operating hours in 100-hour units. 4 Exit the Operating Hours Log.
TROUBLESHOOTING ● Before beginning . . . . . . . . . . . .6-2 ● A few words of caution . . . . . . .6-2 ● How to identify the cause of a problem . . . . . . . . . . . . . . .6-3 DIAGNOSTICS ● Shut down alarms . . . . . . . . . . .6-4 ● Warning alarms . . . . . . . . . . . .6-10 ● System alarms . . . . . . . . . . . . .6-11 ● Chiller will not power up . . . . .6-12 REPAIR ● Checking and replacing fuses .6-13 ● Resetting overloads . . . . . . . . .6-14 ● Replacing the pump overload .
BEFORE BEGINNING You can avoid most problems by following the recommended installation, operation and maintenance procedures outlined in this User Guide. If you do have a problem, this section will help you determine what caused it and tell you how to fix it. Before you begin troubleshooting: ❏ Find the wiring, plumbing and other diagrams that were shipped with your equipment. These diagrams are the best reference for correcting a problem.
Most chiller malfunctions are indicated by an illuminated alarm light and error codes displayed on the control panel. A problem can trigger three types of alarms: ● Shut Down Alarms: The chiller detected a problem that caused it to shut down automatically to prevent equipment damage or personal injury. ● Warning Alarms: The chiller continues to operate, but warns of a problem that could lead to a condition that will shut down the unit.
The chiller has detected a problem that could lead to equipment damage or personal injury if it is not corrected. ◆ The Alarm LED lights and the STOP/RUN LED flashes red. ◆ The chiller automatically shuts down. ◆ The control displays a red LED or alarm code indicating the source of the problem. SHUT DOWN ALARMS Alarm Pump The pump motor overload has tripped. The contact is open.
The chiller has detected a problem that could lead to equipment damage or personal injury if it is not corrected. ◆ The Alarm LED lights and the STOP/RUN LED flashes red. ◆ The chiller automatically shuts down. ◆ The control displays a red LED or alarm code indicating the source of the problem. Alarm Lo SAF Actual temperature of water supplied to the process is below the programmed 10° F safety limit.
The chiller has detected a problem that could lead to equipment damage or personal injury if it is not corrected. ◆ The Alarm LED lights and the STOP/RUN LED flashes red. ◆ The chiller automatically shuts down. ◆ The control displays a red LED or alarm code indicating the source of the problem. SHUT DOWN ALARMS Alarm PHS Err Possible cause Solution Is the pump rotating in the wrong direction? Check pump rotation against the arrow stamped on the pump.
SHUT DOWN ALARMS The chiller has detected a problem that could lead to equipment damage or personal injury if it is not corrected. ◆ The Alarm LED lights and the STOP/RUN LED flashes red. ◆ The chiller turns off the compressor, but normal operation resumes after you clear the alarm or the problem corrects itself. ◆ The control displays a red LED or alarm code indicating the source of the problem. Alarm Compressor The compressor overload has tripped.
SHUT DOWN ALARMS The chiller has detected a problem that could lead to equipment damage or personal injury if it is not corrected. ◆ The Alarm LED lights and the STOP/RUN LED flashes red. ◆ The chiller turns off the compressor, but normal operation resumes after you clear the alarm or the problem corrects itself. ◆ The control displays a red LED or alarm code indicating the source of the problem. Alarm Refrigerant Pressure Refrigerant pressure is either too low or too high.
The chiller has detected a problem that could lead to equipment damage or personal injury if it is not corrected. ◆ The Alarm LED lights and the STOP/RUN LED flashes red. ◆ The chiller turns off the compressor, but normal operation resumes after you clear the alarm or the problem corrects itself. ◆ The control displays a red LED or alarm code indicating the source of the problem. Alarm Refrigerant Pressure Refrigerant pressure is either too low or too high.
The chiller has detected a problem that could lead to a shut down condition if it is not corrected. ◆ The Alarm LED lights. ◆ The chiller continues operating. ◆ The control displays a red LED or alarm code indicating the source of the problem. WARNING ALARMS Alarm Low Deviation The actual temperature of fluid supplied to the process is lower than the setpoint deviation limit allows. High Deviation The actual temperature of fluid supplied to the process is higher than the setpoint deviation allows.
The chiller has detected a non-recoverable error involving he microprocessor control. ◆ The Alarm LED lights and the STOP/RUN LED flashes red. ◆ The chiller shuts down or will not start. ◆ The control displays an error code indicating the source of the problem. Alarm ERR 001 RAM hardware failure. ERR 002 ROM, checksum failure. ERR 003 ERR 004 SYSTEM ALARMS Cause Solution Electrical noise or failed CPU on the motherboard caused system write tests do fail during power up.
CHILLER WILL NOT POWER UP If you apply power to the chiller and the control panel does not light, you have a problem with the main power circuit or the unit’s microprocessor board. Symptom Possible cause Solution Applying power does not turn on the chiller or light the control panel. Is power reaching the chiller? ❒ Verify that the main power supply and any customerinstalled electrical disconnect or emergency stop devices are in the ON position.
This procedure covers the factory-installed fuses on the unit’s motherboard. If you have installed an electrical disconnect or emergency stop switch, additional fuses and/or breakers may have been used elsewhere in the in the main power circuit. To replace a blown fuse: 1 Disconnect and lockout the main power. 2 3 4 CHECKING AND REPLACING FUSES Open the electrical enclosure door. Turn the screw on the front panel counterclockwise to open. WARNING: Replace the fuse.
RESETTING OVERLOADS REPLACING THE PUMP OVERLOAD The pump motor overload is located inside the unit’s electrical enclosure. 1 Disconnect and lockout the main power. 2 Open the electrical enclosure door. Turn the screw on the front panel counterclockwise to open. 3 Check the overload. 1 Disconnect and lockout the main power. 2 Open the electrical enclosure door. Turn the screw on the front panel counterclockwise to open. 3 4 MOTOR CON- If the yellow button is out, the overload has tripped.
1 Disconnect and lockout the main power supply. 2 Open the electrical enclosure door.
REPLACING THE COMPRESSOR CONTACTOR IMPORTANT: Always refer to the wiring diagrams that came with your chiller to locate specific electrical components. Illustrations in the User Guide are intended to be representative only. WARNING: Electrical Shock Hazard Only qualified service personnel who have been trained on electrical testing and the procedures for avoiding the hazards should diagnose or correct problems that require opening the unit with power on.
The unloader valve is located between the compressor and the condenser on both air-cooled and water-cooled chillers. It works only during low demand conditions, when loads are up to 24% below normal. During low-load conditions, the compressor cycles off. To decrease the frequency of cycling, which is harmful to the compressor, the microKool uses an unloader valve to channel some of the hot refrigerant gas from the compressor directly back into the condenser.
WARNING: Electrical shock hazard REPLACING THE FREEZESTAT Before attempting maintenance of any kind, stop the unit and disconnect and lock out the main power supply. The freezestat unit is a bulb and capillary thermostat. To replace the unit: 1 Shut down the chiller and disconnect the process fluid lines. 2 3 Disconnect and lockout the power supply. Drain the tank of all fluid through the drain valve in the base of the tank. 4 Locate the freezestat bulb.
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.
EQUIPMENT GUARANTEE PERFORMANCE WARRANTY 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 SPI commands supported by Conair microKool portable chillers are listed in the following tables. The standard required commands and three optional commands are listed in the SPI Command Pairs table, along with the Select and Poll command pairs in hexadecimal format. Select commands set or change chiller functions. Poll commands retrieve information from the chiller.
SPI STATUS WORDS Status, Process Reserved Reserved Alarm, Low flow Reserved Alarm, Low pressure condition Alarm, High pressure condition Alarm, Low temperature deviation Alarm, High temperature deviation 13 12 11 10 9 8 7 6 5 4 EEprom error A/D converter error CJC Error RAM hardware ROM checksum Probe Failure Processing Reserved 14 Alarm, System Reserved 15 Alarm, Process Open Word BIT position Alarm, Machine SPI STATUS WORD Open Poll: 0x21 0x40 3 2 1 0 SET SET SET SET S
SPI STATUS WORDS Status, Machine 1 Alarm, Low volts Alarm, High volts Reserved Reserved Alarm, Low pressure safety limit Alarm, High pressure safety limit Alarm, Low temperature safety limit Alarm, High temperature safety limit 13 12 11 10 9 8 7 6 5 4 Processing Alarm, High current 14 Alarm, System Alarm, Low current 15 Alarm, Process Alarm, Phase Word BIT position Alarm, Machine SPI STATUS WORD Open Poll: 0x21 0x42 3 2 1 0 SET SET SET SET SET SET SET SET SET SET SET SE
SPI STATUS WORDS Status, Machine 2 Reserved Reserved Reserved Reserved Reserved Reserved Fault, CAL Fault, Sensor 13 12 11 10 9 8 7 6 5 4 EEprom error A/D converter error CJC Error RAM hardware ROM checksum Probe Failure Processing Reserved 14 Alarm, System Reserved 15 Alarm, Process Open Word BIT position Alarm, Machine SPI STATUS WORD Open Poll: 0x21 0x44 3 2 1 0 SET SET SET SET SET SET SET SET SET SET SET SET * * * * * * * * * * * * * * * * * * * * SET E/M Hi temp
PARTS/DIAGRAMS ● PC-1 Wiring Diagram . . . . . . . .PD-2 ● PC-1 Circuit Board . . . . . . . . .PD-3 ● PC-2 Wiring Diagram . . . . . . . .PD-4 ● PC-2 Circuit Board . . . . . . . . .PD-5 ● Parts Lists . . . . . . . . . . . . . . . .
PD-2 PC-1 WIRING DIAGRAM UGH004/0999
L2 L3 L2 L3 L1 L1 4 11 H P H S/L PS P 11 /L S PS 13 O PS 13 O P 14 1 S J TA N UM 1T S OT PE A U R S SE W D HE N 3 4 3 2 1 OPS OPS FSTAT FSTAT F1 6 5 4 3 2 1 LLS/WPS LLS/WPS NOT USED NOT USED HPS/LPS HPS/LPS 4 FR O FR M O T C M RA O T N O MP RA SF PT C N R .
PD-4 PC-2 WIRING DIAGRAM UGH004/0999
L2 L3 L2 L3 L1 L1 13 14 11 13 4 11 3 4 3 2 1 OPS OPS FSTAT FSTAT F1 6 5 4 3 2 1 LLS/WPS LLS/WPS AUTOSTART AUTOSTART HPS/LPS HPS/LPS 4 4 19 FR O FR M O T C M RA O T N O MP RA SF PT C N R .
