Conair MPA, MPW, microKool MPA, microKool MPW User Manual

It’s a good idea to record the model and serial number(s) of your equipment and the date you received it in the User Guide. Our service department uses this information, along with the manual number, to provide help for the specific equipment you installed.

Please keep this User Guide and all manuals, engineering prints and parts lists together for documentation of your equipment.

Date: Manual Number: UGH004/0999

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 damages in connection with the furnishing, performance or use of this information. Conair makes no warranty of any kind with regard to this information, including, but not limited to the implied warranties of merchantability and fitness for a particular purpose.

Please record your

equipment’s model and

serial number(s) and

the date you received it

in the spaces provided.

THE CONAIR GROUP, INC.

UGH004/0999 microKool Portable Chillers

TABLE OF CONTENTS

NTRODUCTION . . . . . . . . . . . . . . . . . . .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

DESCRIPTION . . . . . . . . . . . . . . . . . . . .2-1

What is the microKool chiller? . . . . . . . . . . . . . . . . . . . . . .2-2

Typical applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2

How it works: Water-Cooled . . . . . . . . . . . . . . . . . . . . . . .2-3

How it works: Air-Cooled . . . . . . . . . . . . . . . . . . . . . . . . .2-4

Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-5

Specifications: Water-Cooled . . . . . . . . . . . . . . . . . . . . . . .2-6

Specifications: Air Cooled . . . . . . . . . . . . . . . . . . . . . . . . .2-7

Freeze protection requirements . . . . . . . . . . . . . . . . . . . . .2-8

INSTALLATION . . . . . . . . . . . . . . . . . . . .3-1

Unpacking the boxes . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2

Preparing for installation . . . . . . . . . . . . . . . . . . . . . . . . . .3-3

Connecting the proces and water supply lines . . . . . . . . . . .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) . . . . . .3-12

Enabling the Auto Start feature

(PC-2 control) . . . . . . . . . . . .3-14

Activating SPI communication . . . . . . . . . . . . . . . . . . . . .3-16

OPERATION . . . . . . . . . . . . . . . . . . . . . .4-1

PC-1 control features . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2

PC-2 control features . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-3

Positioning the control panel . . . . . . . . . . . . . . . . . . . . . . .4-4

Starting the chiller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-5

Entering passcodes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-6

Stopping the chiller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-7

Using the pumpdown feature

(PC-2 control) . . . . . . . . . . . . . .4-9

Performing an Auto Tune . . . . . . . . . . . . . . . . . . . . . . . . .4-10

MAINTENANCE . . . . . . . . . . . . . . . . . . . .5-1

Preventative maintenance schedule . . . . . . . . . . . . . . . . . . .5-2

Cleaning evaporators . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-4

Cleaning condensers . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-4

Refilling the tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-5

Checking refrigerant charge . . . . . . . . . . . . . . . . . . . . . . . .5-6

TABLEOF CONTENTS

AINTENANCE . . . . . . . . . . . . . . .(continued)

Performing System Tests . . . . . . . . . . . . . . . . . . . . . . . . . .5-7

The Key/Display Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-8

Input Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-9

Output Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-10

Disabling and Enabling Outputs . . . . . . . . . . . . . . . . . . . .5-11

Calibrating Temperature Sensors . . . . . . . . . . . . . . . . . . .5-12

Logging Operating Hours . . . . . . . . . . . . . . . . . . . . . . . .5-13

TROUBLESHOOTING . . . . . . . . . . . . . . . .6-1

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 and Replacing Overloads . . . . . . . . . . . . . . . . .6-14

Replacing the Motherboard . . . . . . . . . . . . . . . . . . . . . . .6-15

Replacing the compressor contactor . . . . . . . . . . . . . . . . .6-16

Checking the unloader valve . . . . . . . . . . . . . . . . . . . . . .6-17

Replacing the freezestat . . . . . . . . . . . . . . . . . . . . . . . . . .6-18

APPENDIX

Customer Service Information . . . . . . . . . . . . . . . . . . . . . .A-1

Warranty/Guarantee Information . . . . . . . . . . . . . . . . . . . .A-2

microKool SPI commands . . . . . . . . . . . . . . . . . . . . . . . . .B-1

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

microKool Portable Chillers UGH004/0999

1-1

UGH004/0999 microKool Portable Chillers

●●

Purpose of the User Guide . . . .1-2

●●

How the guide is organized . . . .1-2

●●

Your responsibilities as a user .1-2

●●

ATTENTION: Read this so

no one gets hurt . . . . . . . . . . .1-3

INTRODUCTION

microKool Portable Chillers UGH004/0999

1-2 INTRODUCTION

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. This review won’t take long, and it could save you valuable installation and operating time later.

Symbols have been used to help organize the User Guide and call your attention to important information regarding safe installation and operation.

Symbols within triangles warn of conditions that could be hazardous to users or could damage equipment. Read and take precautions before proceeding.

Numbers within shaded squares indicate tasks or steps to be performed by the user.

A diamond indicates the equipment’s response to an action performed by the user.

An open box marks items in a checklist. A shaded circle marks items in a list.

You must be familiar with all safety procedures concerning installation, operation and maintenance of this equipment. Responsible safety procedures include:

● Thorough review of this User Guide, paying particular

attention to hazard warnings, appendices and related diagrams.

● Thorough review of the equipment itself, with careful

attention to voltage requirements, intended uses and warning labels.

● Thorough review of instruction manuals for associated

equipment.

● Step-by-step adherence to instructions outlined in this

User Guide.

PURPOSE OF THE USER GUIDE

HOW THE GUIDE IS ORGANIZED

◆ ❒

●

YOUR RESPONSIBILITY ASAUSER

UGH004/0999 microKool Portable Chillers

INTRODUCTION 1-3

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: Electrical shock hazard

This equipment is powered by three-phase main voltage, as specified on the machine serial tag and data plate.

Always disconnect and lock out the incoming main power source before opening the electrical enclosure or performing non-standard operating procedures, such as troubleshooting or maintenance. Only qualified personnel should perform procedures that require access to the electrical enclosure while power is on.

WARNING: Improper installation, operation or servicing may result in equipment damage or personal injury.

This equipment should be installed, adjusted, and serviced by qualified technical personnel who are familiar with the construction, operation and potential hazards of this type of equipment.

All wiring, disconnects and fuses should be installed by qualified electrical technicians in accordance with electrical codes in your region.

Always maintain a safe ground. A properly sized conductive ground wire from the incoming power supply must be connected to the chassis ground terminal inside the electrical enclosure. Improper grounding can result in personal injury and erratic machine operation.

Do not operate the equipment at power levels other than what is specified on the the equipment serial tag and data plate.

Only certified refrigerant technicians should recharge the refrigerant used in this system.

2-1

UGH004/0999 microKool Portable Chillers

●●

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 . . . . . . . . . . . . . .2-8

DESCRIPTION

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.

Air-cooled models use 95° F (35° C) ambient air and aluminum-fin, copper-tube condensers. Units above 1.5 Hp include automatic fan cycling controls.

Units are totally self-contained for easy, economical installation. To operate, simply connect the power source, process piping and fill with water or an industrial antifreeze mixture.

The standard PC-1 microprocessor control displays setpoint and actual temperature of the process fluid, and provides SPI communication. Nine operating and fault indicator lights display the status of the chiller components.

The enhanced PC-2 control offers the same features as the standard control plus autostart capabilities, which enables the chiller to start automatically with a timing device or the starting of the primary process machine.

These chillers are ideal for cooling to maintain process temperatures in an injection molding machine or extruder and wherever you need a small, moveable cooling unit.

Capacities range from 1.2 to 10.2 tons. Standard operating setpoints are between 20° F (-7° C) and 65° F (19° C) LWT. Adequate freeze protection is required.

Choose water-cooled portable chillers:

● for maximum capacity and minimal maintenance.

● when maintaining ambient air temperature is important,

such as an air-conditioned environment.

● when tower water or another inexpensive water source is

available.

Choose air-cooled portable chillers.

● when plant water supply is inadequate or limited.

● when process heat must be extracted and used for space

heating.

WHAT IS THE

MICRO

KOOL

CHILLER?

microKool Portable Chillers UGH004/0999

2-2 DESCRIPTION

TYPICAL APPLICATIONS

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.

The refrigerant passes through a thermal expansion valve, where it expands, cools and is precisely metered into the refrigerant heat exchanger (evaporator).

The evaporator removes the heat from the process fluid.

HOW IT WORKS: W

ATER COOLED

UGH004/0999 microKool Portable Chillers

DESCRIPTION 2-3

Typical water-cooled plumbing diagram

HOW IT WORKS: A

IR COOLED

microKool Portable Chillers UGH004/0999

2-4 DESCRIPTION

Air-cooled models use aluminum-finned, copper tube condensers to condense the hot, compressed, refrigerant gas from the compressor to a cool liquid.

The refrigerant passes through a thermal expansion valve, where it expands, cools and is precisely metered into the refrigerant heat exchanger (evaporator).

The evaporator removes the heat from the process fluid.

Typical air-cooled plumbing diagram

UGH004/0999 microKool Portable Chillers

DESCRIPTION 2-5

Molded Plastic Reservoirs

Large,thick-walled, insulated polyethylene reservoirs provide corrosion-free operation. Low-water level sensors, external fill ports and level indicators are standard.

Water Connections

All chilled water and condenser water connections are welded to the structure. Ever y unit includes bronze chilled water supply and return valves.

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.

Corrosion-Free Evaporators

On models through 7.5 Hp, chilled water flows through heavy gauge tube-in-tube evaporators.The water comes in contact with only copper surfaces, eliminating corrosion and scale build-up that can severely reduce chiller efficiency. Low pressure drops, averaging less than 2 psi, result in more flow to the process.

Performance-engineered condensers

Water-cooled models are equipped with high efficiency, non-ferrous tube-in-tube condensers and water regulating valves.Air-cooled models have aluminum fin, copper tube condensers. MPA models with compressors above 1.5 Hp have automatic fan cycling controls.

Control Extension

Controls can be extended approximately 11 inches from the control base.

FEATURES

Water-cooled unit shown

SPECIFICATIONS: MPW (WATER COOLED)

microKool Portable Chillers UGH004/0999

2-6 DESCRIPTION

MODEL MPW-1.5 MPW-2 MPW-3 MPW-4 MPW-5 MPW-7.5 MPW-10 Performance characteristics

Capacity {tons}

1.4 1.8 3.1 4.1 4.8 7.6 10.2 Compressor Hp {kW} 1.5 {1.12} 2 {1.49} 3 {2.24} 4 {2.98} 5 {3.73} 7.5 {5.59} 10 {7.45} Pump Hp {kW}

†

0.33 {0.246} 0.50 {0.373} 0.75 {0.559} 1.5 {1.12} 1.5 {1.12} 1.5 {1.12} 1.5 {1.12}

Chilled water flow gpm {l/min}

‡

3.4 {12.9} 4.5 {17.0} 7.5 {28.3} 9.9 {37.5} 11.4 {43.2} 18.2 {68.9} 24.5 {81.0}

Chilled water pressure psi {bar}

20 {1.4} 26 {1.8} 34 {2.3} 38 {2.6} 38 {2.6} 37.5 {2.6} 37 {2.5} Reservoir capacity gal (l) 10 {37.9} 10 {37.9} 10 {37.9} 30 {114} 30 {114} 30 {114} 30 {114} Condenser water flow gpm {l/min} 4.3 {16.3} 5.6 {21.2} 9.4 {35.6} 12.4 {47.0} 14.3 {54.2} 22.8 {86.4} 30.6 {116.0}

Dimensions inches {mm}

A - Height

45 {1143} 45 {1143} 45 {1143} 56 {1422} 56 {1422} 70 {1778} 70 {1778} B - Depth 32 (812} 32 {812} 32 {812} 48 {812} 48 {812} 48 {812} 48 {812} C - Width 29 {737} 29 {737} 29 {737} 34 {737} 34 {737} 34 {737} 34 {737}

Weight lb {kg}

Shipping weight 550 {249} 755 {342} 755 {342} 1010 {458} 1010 {458} 1250 {567} 1250 {567} Installed weight 420 {190} 585 {265} 585 {265} 840 {381} 840 {381} 1080 {490} 1080 {490}

Utility requirements

Water connections NPT (female) inches 1 1 1 1.5 1.5 1.5 1.5 Process and condenser water inches 1 1 1 1.5 1.5 1.5 1.5

Voltages running and full load amps run full run full run full run full run full run full r un full

208V/3 phase/60hz 8.8 15.5 13.7 15.9 17.7 22.3 23.9 28.3 27.0 30.5 34.9 41.5 44.2 50.8 230V/3 phase/60hz 8.0 14.0 12.4 14.4 16.0 20.2 21.6 25.6 24.4 27.6 31.6 37.6 40.0 46.0 460V/3 phase/60hz 4.0 7.0 6.2 7.2 8.0 10.1 10.8 12.8 12.2 13.8 15.8 18.8 20.0 23.0 575V/3 phase/60hz 3.2 5.6 5.0 5.8 6.4 8.1 8.6 10.2 9.8 11.0 12.6 15.0 16.0 18.4

Flow Rate (gpm)

Pressure (psi)

SPECIFICATION NOTES

* Based on 50° F (10° C) water temperature (100% water) leaving the chiller, standard pump selections, 85° F (27° C) condenser water supply

@ 25 psi minimum. Consult factory for other conditions.

†

Standard pump selection. Larger pumps available as options.

‡

Based on 50° F water temperature leaving the chiller and 60° F (15° C) water temperature returning to the chiller.

Pressure at pump discharge.

** Control can be extended upward approximately 11 inches, which may or may not increase the overall height of the unit.

Specifications may change without notice.Check with a Conair representative for the most current information.

60 HZ PUMP PERFORMANCE CURVES

SPECIFICATIONS:MPA (AIR COOLED)

UGH004/0999 microKool Portable Chillers

DESCRIPTION 2-7

MODEL MPA-1.5 MPA-2 MPA-3 MPA-4 MPA-5 MPA-7.5 MPA-11 Performance characteristics

Capacity {tons}

1.2 1.7 2.7 3.5 4.1 6.9 10.2 Compressor Hp {kW} 1.5 {1.12} 2.25 {2.05} 3.25 { 279.7} 4 {2.98} 5 {3.73} 9 {6.71} 12 {8.95} Pump Hp (kW)

†

0.33 {0.246} 0.50 {0.373} 0.75 {0.559} 1.5 {1.12} 1.5 {1.12} 1.5 {1.12} 1.5 {1.12}

Chilled water flow gpm {l/min}

‡

2.8 {10.6} 4.2 {15.9} 6.4 {24.2} 8.5{32.1} 9.9 {37.5} 16.6 {62.8} 24.5 {92.7}

Chilled water pressure psi {bar}

20 {1.4} 26 {1.8} 34 {2.3} 38 {2.6} 38 {2.6} 37.5 {2.6} 37 {2.5} Reservoir capacity gal {l} 10 {37.9} 30 {114} 30 {114} 30{ 114} 30 {114} 30 {114} 40.5 {153} Number of condenser fans 1 2 2 2 2 2 4 Condenser fan power Hp {kW} 0.063 {0.047} 0.063 {0.047} 0.063 {0.047} 0.063 {0.047} 0.063 {0.047} 0.50 {0.047} 0.50 {0.047} Condenser air flow ft3/min {l/min} 1050 {496} 1704 {804} 2420 {1142} 4237 {2000} 4237 {2000} 5300 {2501} 8400 {3964}

Dimensions inches {mm}

A - Height

45 {1143} 48 {1129} 48 {1129} 56 {1422} 56 {1422} 70 {1778} 76 {1930} B - Depth 32 {812} 44 {1118} 44 {1118} 48 {1219} 48 {1219} 48 {1219} 48 {1219} C - Width 29 {737} 29 {737} 29 {737} 34 {737} 34 {737} 34 {737} 40{1016}

Weight lb {kg}

Shipping weight 750 {340} 1000 {454} 1000 {454} 1200 {544} 1200 {544} 1400 {635} 1600 {726} Installed weight 610 {277} 830 {376} 830 {376} 1030 {467} 1030 {467} 1230 {558} 1430 {649}

Utility Requirements

Water connections NPT (female) inches 1 1 1 1.5 1.5 1.5 1.5 Process water inches 1 1 1 1.5 1.5 1.5 1.5

Voltages running and full load amps run full run full run full run full run full run full run full

208V/3 phase/60hz 11.7 18.3 16.1 18.6 21.0 27.0 27.8 32.3 31.0 34.5 63.0 69.6 90.8 97.8 230V/3 phase/60hz 10.6 16.6 14.6 16.8 19.0 24.4 25.2 29.2 28.0 31.2 57.0 63.0 82.2 88.5 460V/3 phase/60hz 5.3 8.3 7.3 8.4 9.5 12.2 12.6 14.6 14.0 15.6 28.5 31.5 41.1 44.3 575V/3 phase/60hz 4.2 6.6 5.8 6.7 7.6 9.8 10.1 11.7 11.2 12.5 22.8 25.2 32.9 35.4

SPECIFICATION NOTES

* Based on 50° F (10° C) water temperature (100% water) leaving the chiller, standard pump selections, 95° F (35° C)ambient air conditions.

Consult factory for other conditions.

†

Standard pump selection. Larger pumps available as options.

‡

Based on 50° F water temperature leaving the chiller 60° F (15° C) water temperature returning to the chiller.

Pressure at pump discharge. ** Control can be extended upward approximately 11 inches, which may or may not increase the overall height of the unit. Specifications may change without notice.Check with a Conair representative for the most current information.

Flow Rate (gpm)

60 HZ PUMP PERFORMANCE CURVES

Pressure (psi)

FREEZE PROTECTION REQUIREMENTS

microKool Portable Chillers UGH004/0999

2-8 DESCRIPTION

60 50 40 30 20 10

-10

-20

-30

-40

-50

-60 2004060

100

40 30 20 10

-10

-20

-30

-40

-50

-60

-70

-80 2004060

100

Freeze Protection Requirements

by Unit Set Temperature

Freezing Points of Aqueous

Ethylene Glycol Solutions

Ethylene Glycol, % by weight

Temperature, degrees F

to Process Set Temperature, degrees F

3-1

UGH004/0999 microKool Portable Chiller

●●

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)

. . . . .3-12

●●

Installing the Auto Start

feature . . . . . . . . . . . . . . . . . .3-14

●●

Activating SPI

communication . . . . . . . . . . . .3-16

INSTALLATION

UNPACKING THE BOXES

microKool Portable Chillers UGH004/0999

3-2 INSTALLATION

Carefully remove the chiller and components from

their shipping containers, and set upright.

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.

Carefully inspect all components to make sure no

damage occurred during shipping, and that you have all the necessary hardware. If damage is found, notify the freight company immediately.

Take a moment to record serial numbers and

specifications in the blanks provided on the back of the User Guide’s title page. The information will be helpful if you ever need service or parts.

You are now ready to begin installation.

Complete the preparation steps on the next page.

MicroKool Portable Chillers come fully assembled.

UGH004/0999 microKool Portable Chillers

INSTALLATION 3-3

The microKool chiller is easy to install, if you plan the location and prepare the area properly.

Position the chiller as close to the process machine as possible.

Make sure the installation area provides:

❒❒

A three-phase power source supplying the correct

current for your chiller model. Check the serial tag on the

side of the electrical enclosure for the required voltage, phase, frequency, full load amps, disconnect fuse size and minimum wire connection size. Field wiring should be completed by qualified personnel to the planned location for the chiller. All electrical wiring should comply with your region’s electrical codes.

❒❒

A clean, well-ventilated environment.

The room temperature should not exceed 110° F (43° C) with 95% non-condensing humidity and should not fall below 55° F (12° C).

❒❒

Minimum clearance for safe operation and mainte-

nance. Nothing should be placed on top of the unit while

the unit is operating. All models require a minimum clearance of 5 ft. around the perimeter for servicing. Models equipped with fans also require unrestricted outlet air flow.

❒❒

A source of water for cooling on water-cooled units.

City, tower or chiller water may be used, as long as the supply pressure is at least 25 psi and not more than 85 psi.

Install plumbing for process and cooling lines.

See the specification tables for the correct line and fitting sizes. Larger line sizes are acceptable as long as they are reduced at the chiller connections. Smaller line sizes are not recommended.

PREPARING FOR INSTALLATION

Process machine

Chiller

Alternate locations

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.

Remove the shipping pipe plug from the female

connections on the back of the chiller.

Install pipe to the rear of the chiller.

Use appropriately sized male NPT piping for the process connections and the MPW condenser water connections.

Pipe and pipe threads must be clean and new. Clean threads with solvent, removing all oil, grease and dirt. Allow the threads to dry before proceeding.

Coat the pipe threads with thread sealant.

Follow the sealant manufacturer’s directions.

Connect the male pipe to the appropriate female connection on the back of the unit

. Connections are labeled on the chiller. Start by hand until the threads engage, then use a pipe wrench to tighten the connection only enough to prevent leaks.

Do not over-tighten!

CONNECTING PROCESS AND WATER SUPPLY LINES

microKool Portable Chillers UGH004/0999

3-4 INSTALLATION

Tools for installation:

❒ Pipe wrench large enough

for a 2-inch pipe

❒ Premium quality Teflon

thread sealant

Process connections (NPT):

MPW-1.5 MPW-2 MPW-3 MPW-4 MPW-5 MPW-7.5 MPW-10

MPA-1.5 MPA-2 MPA-3 MPA-4 MPA-5 MPA-7.5 MPA-11

1 in. 1 in. 1 in. 1.5 in. 1.5 in. 1.5 in. 1.5 in.

Condenser water connections (NPT):

MPW-1.5 MPW-2 MPW-3 MPW-4 MPW-5 MPW-7.5 MPW-10

1 in. 1 in. 1 in. 1.5 in. 1.5 in. 1.5 in. 1.5 in.

NOTE: Make sure the chiller tank is full of process fluid before you begin operating. Use a glycol mixture if operating temperatures are below 45° F. See

REEZEPROTECTION

EQUIREMENTS

Tank

fill port

Condenser

water in

From

Process

Condenser

water out

Condenser water connections on MPW models only

Process

Tank level

sight glass

UGH004/0999 microKool Portable Chillers

INSTALLATION 3-5

Before beginning, note the electrical specifications on the nameplate mounted to the side of the unit. The electrical

hookup must match these specifications with +/- 10% maximum voltage variance. An improper power supply could damage the unit as well as seriously injure an operator.

The electrical hookup also should run through a fused disconnect sized for the nameplate amperage and conforming to Article 250 of the National Electrical Code.

Open the unit’s electrical enclosure. Insert the main power wire

through the knockout

hole in the right side of the enclosure.

Secure the power wire with a rubber compression fitting or strain relief.

Connect the power wires to the terminals.

Connect the three hot wires to L1, L2, and L3 on the terminal block.

Connect the ground wire

to the copper grounding mount. If you have installed a disconnect device, follow the manufacturer’s wiring instructions.

1 2

3 4

CONNECTING THE MAIN POWER SUPPLY

WARNING: Electrical shock hazard

This equipment is powered by three-phase main voltage.Always disconnect and lock out the main power source before perfor ming any work involving electrical connections.All wir ing, disconnects and fusing should conform to your region’s electrical codes and should be installed only by qualified personnel.

IMPORTANT: Always refer to the wiring diagrams that came with your unit before making electrical connections.The diagrams show the most accurate electrical component information.

IMPORTANT! Before initiating power to the unit:

❒ Check the system for leaks. ❒ Verify that the voltage, phase,

frequency, amperage, disconnect fuse and minimum wire size meet the specifications stated on the nameplate mounted on the side of the unit.

❒ Verify that resistance to ground on

each phase is at least 1 meg ohm.

microKool Portable Chillers UGH004/0999

Turn on the condenser water supply (MPW units) and check for leaks.

If any leaks appear, stop the test and fix the problem before continuing. The water pressure must be at least must be at least 25 PSI at the condenser inlet.

Apply power to the unit.

◆ Indicator lights on the control panel blink green, then

red, to test operation of the LEDs.

◆ Setpoint and actual windows will display for

three seconds, followed by the software version. The windows then display the factory default setpoint of 50° F (10° C) and the actual temperature.

Check the rotation of the pump. Remove the

access panel and verify that the pump rotation matches the direction indicated on the rotation stamp on the pump.

NOTE: If the rotation is incorrect, stop the test and disconnect power to the unit. Open the electrical enclosure and switch any two of the three power source wires on the terminal block. Return to Step 2 and check rotation again.

Replace the access panel. Press the RUN key to start the unit.

If everything is working correctly:

◆ The RUN/STOP light turns green.

◆ The pump begins operating. The compressor turns on

after 3 seconds, if the actual temperature is above the setpoint.

◆ Normal operation begins. The unloader valves turn on,

if the actual temperature is below setpoint. The compressor remains active until the actual temperature is 6° F below the setpoint.

The test is over. Proceed to initial setup if the unit operated normally; refer to the

ROUBLESHOOTING

section if it did not.

TESTING THE INSTALLATION

4 5

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.

3-6 INSTALLATION

NOTE: Make sure the chiller tank is full of process fluid before you begin operating.

UGH004/0999 microKool Portable Chillers

INSTALLATION 3-7

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.

The factory default setting is the process temperature setpoint ± 10° F (6° C). This parameter is adjustable to establish a narrower or wider acceptable temperature range for normal operation. You cannot set the Low Deviation below the factory-set Low Safety temperature. The High Deviation cannot be set to exceed the factory-set High Safety temperature.

To change the temperature deviation settings:

Press the Setpoint Select button to select the deviation parameter you want to change.

Use the ▲ and ▼ setpoint buttons to enter the deviation temperature.

The setting is stored in memory even when the power is turned off. The recommended setting is ± 2-10° F.

ENTERING SETPOINT DEVIATION PARAMETERS

FACTORY DEFAULT SETTINGS Model MPW MPA

Process Setpoint 50° F (10° C) 50° F (10° C) High Safety 75° F (24° C) 75° F (24° C) Low Safety 10° F (-12° C) 10° F (-12° C)

NOTE:

If you enabled passcode protection, you must enter

the passcode to change this parameter. See E

NABLING AND

ISABLINGPASSCODEPROTECTION

Too enter the passcode: Hold down the Setpoint Select button for 5 seconds.When the

control displays “ 1 PaS”, use the setpoint adjustment buttons to enter the passcode. Press the Setpoint Select button again. If the correct passcode was entered the controller will display ACC PAS for 3 seconds. If the passcode was incorrect, the controller will display rEJ PAS (rejected passcode).

Access to system parameters remain until power is cycled or the RUN or STOP button is pressed.

microKool Portable Chillers UGH004/0999

3-8 INSTALLATION

INITIAL SETUP

The factory-set parameters and operating modes will satisfy most applications. But you can change some settings and enable or disable features as needed.

You can modify the parameters for high and low process temperature deviation warnings from the control panel. See

ETTINGSETPOINTDEVIATIONPARAMETERS

Dip switches on the motherboard inside the PC-1 and PC-2 electrical enclosure allow you to:

❒ Select the units of measure for tem-

perature displays.

❒ Enable password protection. ❒ Enable the Auto Tune. ❒ Enable the Auto Start feature. ❒ Enable the Test Mode. ❒ Select the source point of tempera-

ture control.

To change the dip switch settings, see the appropriate topic on the following pages.

Dip switch Configuration

No. OFF ON

1 Display units in °F Display units °C 2 Auto Tune disabled Auto Tune enabled 3 Passcode protect Password reset/modify 4 * Auto Start disabled Auto Star t enabled 5 * Control point protect Control point source select 6 Test Mode disabled Test mode enabled 7

†

Controller type selection Controller type selection

†

Controller type selection Controller type selection

* Available only on PC-2 control models. † Switch 7 must be ON, and switch 8 must be OFF. Do not change the settings of these two switches.

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.

NOTE: Dip switch 7 must be ON and dip switch 8 must be OFF for the chiller to work. Do not change the factory setting of these two dip switches.

UGH004/0999 microKool Portable Chillers

CHANGING TEMPERATURE UNITS

The temperature units are factory-set as degrees Celsius or degrees Fahrenheit, as specified when the unit was ordered.

When the chiller is on, the indicator lights to the right of the Actual temperature display on the control panel will show which temperature unit has been set.

To change this setting, move Dip Switch 1 on the control circuit board.

Disconnect and lock out main power to the

chiller.

Open the electrical enclosure. Change Dip Switch 1 to:

OFF for °F ON for °C

Close the electrical enclosure and restore main

power to begin operating.

2 3

INSTALLATION 3-9

WARNING: Electric shock hazard

microKool Portable Chillers UGH004/0999

The PC-1 and PC-2 controls provide the ability to protect system parameters from unauthorized changes during normal operating mode. When system passcode protection is enabled, the following parameters cannot be changed unless you enter the correct passcode:

● The Process Setpoint

● High Deviation Alarm Setpoint

● Low Deviation Alarm Setpoint

● Baud Rate selection for serial communications

● Address selection for serial communications

When the unit is turned on for the first time, passcode protection is disabled. To enable passcode protection:

Disconnect and lock out main power to the unit. Open the electrical enclosure. Set dip switch 3 to ON

and switches 5 and 6 to OFF.

Close the electrical enclosure and restore power to the unit.

Press any button when the control displays “Pas rSt”

(Passcode Reset). The control will display the last passcode used.

Select a new passcode using the ▲▲and

▼▼

setpoint adjustment buttons.

Stop pressing the setpoint buttons when the passcode you want appears in the setpoint display window. Selecting “OFF” as the passcode will disable the passcode feature.

ENABLING AND DISABLING PASSCODE PROTECTION

3-10 INSTALLATION

WARNING: Electric shock hazard

1 2

UGH004/0999 microKool Portable Chillers

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.

Turn off power to the unit. Disconnect and lock out

the main power supply.

Open the electrical enclosure.

Set dip switch 3 to OFF. Close the electrical enclosure and restore

power to the unit.

A passcode now is required to change system parameters.

INSTALLATION 3-11

8 9

10 11

ENABLING AND DISABLING PASSCODE PROTECTION

Disabling Passcode Protection

To disable passcode protection and allow universal access to system parameters:

Follow Steps 1 through 5

in the previous section on enabling passcode protection.

Hold down the

▼▼

setpoint adjustment button

to select “OFF” as the new passcode. Follow steps 7 through 11 in the previous section.

microKool Portable Chillers UGH004/0999

PC-1 microprocessors control the process temperature based upon the average of the temperatures recorded at the supply (to process) and return (from process) thermocouples.

The PC-2 microprocessor allows you to select how the unit will measure and control the process temperature. The control point can be selected as the supply, the return or the average of the the two temperatures.

To select the control point source on units with PC-2 control:

Disconnect and lockout power to the unit. Open the electrical enclosure. Set dip switches 3 and

6 to the OFF position. Set dip switch 5 to the

ON position. Close the electrical enclosure and restore

power to the unit. Press any button when the control displays

“Cnt Pt”.

The controller will display “Sel CnP” and flashes the LED for the current control point.

Select a new control point using the Display button.

Stop pressing the select button until the indicator light next to the control point you want illuminates.

3-12 INSTALLATION

1 2

3 4

5 6

WARNING: Electric shock hazard

SELECTING THE TEMPERATURE CONTROL POINT

(PC-2 CONTROL ONLY)

UGH004/0999 microKool Portable Chillers

SELECTING THE TEMPERATURE CONTROL POINT

(PC-2 CONTROL ONLY)

NSTALLATION 3-13

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.

Turn off power to the unit. Disconnect and lock out

the main power supply.

Open the electrical enclosure.

Set dip switch 5 to OFF.

Close the electrical enclosure and restore power to the unit.

The chiller will now control the process temperature based on actual temperatures recorded at the new control point source.

11 12

microKool Portable Chillers UGH004/0999

3-14 INSTALLATION

If you have a PC-2 microprocessor control, you can automatically start and stop the chiller from a remote switching or timing device that has power contacts rated 110VAC, such as the process machine control.

Wiring the device to the chiller is accomplished through a dry contact to the appropriate terminals on the motherboard. After wiring the device to the unit, Auto Start must be enabled by configuring a dip switch on the motherboard.

Disconnect and lockout power to the unit. Open the electrical enclosure. Punch a small hole in the left side of the

electrical enclosure.

The hole must be large enough to accommodate conduit for the power contact wires from your switching or timing device.

Insert the two power leads from the device

through the conduit into the electrical enclosure.

Connect the 110VAC device contact wires to the Auto Start terminals.

Make sure terminals are

screwed tight.

INSTALLING THE AUTO START FEATURE

(PC-2 CONTROL ONLY)

1 2 3

WARNING: Electric shock hazard

IMPORTANT:

Always refer to the wiring diagrams that came with your unit before making electrical connections.The diagrams show the most accurate electrical component information.

Device contacts

65432

LLS/WPS

AC IN 4

AC IN + 3

AC OUT 2

AC OUT + 1

AUTOST ART

HPS/LPS

AUTOST ART

HPS/LPS

432

OPS

FSTAT

UGH004/0999 microKool Portable Chillers

INSTALLATION 3-15

Set dip switch 4 to the ON position.

Close the electrical enclosure and restore power to the unit.

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.

To disable Auto Start:

Repeat steps 1, 2 and 7, setting dip switch 4 to the OFF instead of the ON position.

INSTALLING THE AUTO START FEATURE

(PC-2 CONTROL ONLY)

6 7

microKool Portable Chillers UGH004/0999

3-16 INSTALLATION

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

To use the SPI communication option, you must connect the chiller to the host machine and set the communication baud rate and node address using the setpoint select and adjustment buttons on the control panel.

Connect the host machine to the chiller.

Plug the male DB9 connector into the serial communications port on the chiller.

Apply power to the chiller. Enter the passcode, if necessary.

Hold the Setpoint Select button for 5 seconds. When the control displays 1 PaS, use the setpoint adjustment buttons to enter the passcode.

Enter the node address.

Press the Setpoint Select button to choose Address. Then press the setpoint ▲ or ▼ arrow until the address you want appears in the setpoint display. The address may be set to any number from 32 to 254 (a hexadecimal integer between 20 and FE), as long as that number has not been assigned to another machine connected to the same network.

Set the baud rate to 12, 24, 48 or 96.

The chiller must be set to send and receive data at the same baud rate as the host machine. Press the setpoint ▲ or ▼ arrow until the baud rate you want appears in the setpoint display window. 12 = 1200 bps 48 = 4800 bps 24 = 2400 bps 96 = 9600 bps

The green SPI status light on the control panel should flash when the unit is communicating. The LED will turn red, indicating an alarm, if SPI communication is not properly set up.

2 3

ACTIVATING SPI C

OMMUNICATION

NOTE:

To disable SPI, use

the setpoint

▲

or ▼arrow to

select Address. Press the

▼

arrow until OFF is displayed in the setpoint window.

See the A

PPENDIX

for additional

SPI programming information.

4-1

UGH004/0999 microKool Portable Chiller

●●

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 . . . . .4-10

OPERATION

All normal operating functions can be controlled from the microKool PC-1 control panel.

PC-1 CONTROL FEATURES

microKool Portable Chillers UGH004/0999

4-2 OPERATION

Setpoint adjustment buttons

Press ▲ or ▼ to enter the process temperature setpoint, SPI parameters and passcodes.

Press ▲ to increase a value. Press ▼ to decrease a value.

TIP: Press and hold the button for faster scrolling speed.

NOTE: Passcode protection prevents accidental or unauthorized changes to all operating parameters. If passcode protection has been enabled, you must enter the correct passcode to change the process temperature setpoint.

Actual values display

The green window displays the temperature at the middle of the process.This is calculated as an average of the process fluid temperatures at the chiller inlet and outlet.

The lights indicate whether the temperature is in degrees Fahrenheit or Celsius. See the

NSTALLATION

section for instructions on how

to change the temperature units.

Setpoint 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.

Setpoint and Actual value display windows also display some alarm codes and setup instructions.

Run/Stop

Press the RUN button to start normal operation. Press STOP to stop the unit.

= Running (green) = Stopped (red) = Alarm (red, flashing)

Status lights

The lights indicate the operating status of the listed components. Except in Test Mode, the lights indicate:

= Off or inactive = On or active (green) = Alarm condition (red)

Test Mode is used for testing displays, keys and input/output functions.When test mode is enabled, normal operation is disabled.

= Test Mode off = Test Mode on (red);

unit disabled

Alarm

Press to acknowledge the alarm light and silence the optional audible alarm.The alarm light will flash until the cause of the alarm condition is fixed. See Troubleshooting for alarm descriptions and remedies.

Setpoint Select button

Press repeatedly until a green light appears next to the parameter you want to program or view.

NOTE: Default settings for the deviation setpoints are: High = setpoint + 10° F Low = setpoint - 10° F A warning alarm occurs (indicator light red) whenever the actual temperature is outside this setpoint range for more than 15 minutes. Recommended setting: ± 2-10° F.

PC-2 CONTROL FEATURES

UGH004/0999 microKool Portable Chillers

OPERATION 4-3

Pumpdown On/Off

The Pumpdown feature prevents refrigerant migration.The compressor turns on and off as needed to store refrigerant in the condenser.

Display Select button

Press repeatedly until a green light appears next to the parameter you want to program or view.

All normal operating functions can be controlled from the microKool PC-2 control panel, including the optional pumpdown feature.

Status lights

The lights indicate the operating status of the listed components. Except in Test Mode and Auto Start, the lights indicate:

= Off or inactive = On or active (green) = Alarm condition (red)

Test Mode is used for testing displays, keys and input/output functions.When test mode is enabled, normal operation is disabled.

= Test Mode off = Test Mode on (red);

unit disabled

Auto Start allows you to start and stop the chiller from a remote switching or timing device, such as the processing machine control. This feature can only ben enabled by configuring a dip switch on the control motherboard.

= Disabled; Auto Start

not available

= Enabled

(flashing green);

unit can start any time

= On and under control of

the remote device

Actual values display

The green window displays the temperature at the middle of the process.The control point for this temperature is selectable as the temperature at the supply outlet, return inlet or the average of the two temperatures.

The lights indicate whether the temperature is in degrees Fahrenheit or Celsius. See the

NSTALLATION

section for instructions on how

to change the temperature units.

Setpoint 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.

Setpoint and Actual value display windows also display some alarm codes and setup instructions.

Run/Stop

Press the RUN button to start normal operation. Press STOP to stop the unit.

= Running (green) = Stopped (red) = Alarm (red, flashing)

Setpoint adjustment buttons

Press ▲ or ▼ to enter the process temperature setpoint, SPI parameters and passcodes.

Press ▲ to increase a value. Press ▼ to decrease a value.

TIP: Press and hold the button for faster scrolling speed.

Alarm

Setpoint Select button

Press repeatedly until a green light appears next to the parameter you want to program or view.

microKool Portable Chillers UGH004/0999

4-4 OPERATION

POSITIONING

THE

CONTROL

PANEL

The control panel on microKool chillers can be swiveled, raised and lowered to provide easy viewing and access. The PC-2 control panel also can be mounted up to 50 feet from the unit, using a remote control cable and the magnetic back on the back of the panel.

To raise and swivel the control panel:

Grasp the black control panel handles, and pull upward. Use the handles to rotate the control panel. Do not rotate the panel 360 degrees.

To lower the control panel:

Grasp the black control panel handles, and rotate the control until it is aligned with the unit. Do not rotate the panel 360 degrees. Gently push down on the handles until the control panel is flush with the unit.

To detach the PC-2 control panel:

The PC-2 control panel may be removed and mounted up to 50 feet from the unit. Do not stretch the cable. The cable is available in various lengths so that you can order the appropriate cable for your installation.

Grasp the black control panel handles and pull upward. Use the magnetic back to mount the control panel in the remote location. Connect the remote-mounted control to the unit with the cable provided.

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.

UGH004/0999 microKool Portable Chillers

OPERATION 4-5

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:

Press and hold the Setpoint Select button for 5 seconds.

The control will display 1 PaS to indi-

cate a passcode is needed.

Press the Select ▲ button until the correct passcode appears in the display.

Press again to enter the passcode.

If the passcode is correct, the control displays ACC PAS for 3 seconds. If the passcode is incorrect, the control displays rEJ PAS (rejected passcode).

Press Setpoint to select the parameter you want to change.

You will have access to the system parameters until:

● The power is cycled off and on.

● The RUN or STOP button is pressed.

● No key has been pressed for 30 seconds.

NOTE: Pressing the STOP or RUN key while you are entering a passcode will abor t the passcode entr y sequence

ENTERING A PASSCODE

2 3

microKool Portable Chillers UGH004/0999

4-6 OPERATION

Before starting the chiller, verify that the system has been installed correctly for your application. See the

NSTALLATION

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.

Turn on main power to the chiller at least 12 hours before you want to begin processing.

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.

◆ Indicator lights blink green, then red.

◆ Setpoint and actual windows will display for

three seconds, followed by the software version. The windows then display the previously entered setpoint and the actual temperature.

Make sure the chiller tank is full of fluid. Turn on the water supply to the chiller (MPW).

The supply must be at least 25 psi. Check for leaks in the condenser water and process fluid lines before continuing.

Enter the passcode, if necessary.

Hold the Setpoint Select button for 5 seconds. When the control displays 1 PaS, use the setpoint adjustment buttons to enter the passcode. Press the Setpoint Select button again.

Enter the temperature setpoint.

Press the Setpoint Select button until the green light appears next to Temperature. Press

▲ to

increase or

▼ to decrease the

temperature setting.

Press to start normal operation.

◆ The RUN/STOP light turns green.

◆ The pump begins operating. The compressor turns on

after 3 seconds, if the actual temperature is above the setpoint.

◆ Normal operation begins. The unloader valves turn on if

the actual temperature is below setpoint. The compressor remains active until the actual temperature is 6° F below the setpoint.

If the Alarm light turns on, press to silence the option- al audible alarm. Then see the

ROUBLESHOOTING

section.

STARTING THE CHILLER

Run

IMPORTANT:

If you are operating the chiller for the first time since installation, you should perform an Auto Tune after two hours of normal operation.You should perform the Auto Tune periodically to ensure that the control correctly calculates how much heat and cooling should be applied to maintain the process setpoint.

See P

ERFORMING ANAUTO

UNE

UGH004/0999 microKool Portable Chillers

OPERATION 4-7

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.

To shut down the unit:

Press .

Disconnect the power supply if you have shut down to service or repair the chiller.

If you have shut down the chiller for relocation or storage, drain all fluid from the unit; disconnect the power supply; and disconnect all process and water connections. In shipment or storage, the chiller can withstand an environment between -40° F (-40° C) and 150° F (65° C) with 95% relative humidity non-condensing.

The microKool must be running to use this feature.

Press the button to turn on Pumpdown.

◆ The green Pumpdown light will flash, indicating the

feature is ready to start when needed.

◆ When Pumpdown is needed, the compressor runs

occasionally to pump refrigerant to the condenser. When Pumpdown is running, the green light remains on but does not flash.

Press the button again to turn off Pumpdown.

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.

Stop

1 2

USING THE PUMPDOWN

FEATURE

(PC-2 CONTROL ONLY)

You should perform an Auto Tune after the first two hours of operation and whenever process variables change (changes in condenser water pressure, piping or molds; large ambient swings; new setpoint temperature) to ensure that the control continues to obtain good approximations of the PID constants used to compensate for the thermal lag of the system.

To ensure a successful Auto Tune, verify that:

❒ The Auto Tune feature has been enabled. Auto Tune is

enabled or disabled via dip switch 2 on the motherboard.

❒ The process value is stable. A fluctuating process value

will fool the software into making inaccurate tuning decisions. The software waits 5 minutes for the process value to stabilize before it starts the Auto Tune process. If the process value still fluctuates after 5 minutes, the Auto Tune terminates and the control displays the “At ti” error.

❒ The control is in STOP mode and the process value is in

ambient temperature. This allows the software to obtain

good approximations of process parameters, which are critical for performing an accurate tune. If this requirement is not met, then a good tune cannot be guaranteed.

❒ The setpoint/process deviation is at least 25° F. If the

absolute value of setpoint - process temperature is not greater than or equal to 25° F, the Auto Tune will terminate. The control will display an “At dEV” error.

Press to shut down the chiller. Disconnect and lock out main power to the unit. Enable A uto Tune.

Open the electrical enclosure. Set dip switch 2 to ON. Close the electrical enclosure and restore power to the unit.

Restore power to the unit.

PERFORMING AN AUTO TUNE

microKool Portable Chillers UGH004/0999

4-8 OPERATION

WARNING: Electric shock hazard

1 2

Stop

Press 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.” If a fault occurred, the control will display the appropriate error message.

PERFORMING AN AUTO TUNE

UGH004/0999 microKool Portable Chillers

OPERATION 4-9

Run

ERROR MESSAGE ERROR DESCRIPTION

Insufficient setpoint/process deviation.

If the absolute value of (setpoint - process value) is less than 25° F. The Auto Tune cannot be started until the temperature difference is at least 25° F.

Auto Tune timed out. Auto Tune will time out if a stable process value cannot be obtained 5 minutes into the tune, or if the tuning process takes longer than 30 minutes.If this error occurs, verify that you followed every requirement under “To ensure a successful Auto Tune” and perform a second tune.

Invalid PID constants were generated.

The most likely causes of this error is a tune started inappropriately or an external element (i.e., loose thermocouple) that upset the process while tuning was in progress. Verify that you followed every requirement under “To ensure a successful Auto Tune” and perform a second tune.

dEvAt

badAt

5-1

UGH004/9499 microKool Portable Chillers

●●

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 . . . . . . . . . .5-11

●●

Calibrating temperature

sensors . . . . . . . . . . . . . . . . . .5-12

●●

Logging operating hours . . . . .5-14

MAINTENANCE

microKool Portable Chillers UGH004/0999

5-2 MAINTENANCE

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.. You should perform an Auto Tune after the first two hours of operation and whenever the process changes, such as after a mold change; installation of different pipe sizes; or change in process setpoint. See

ERFORMING AN

UTOTUNE

in the

PERATION

section.

●●

Weekly, or as often as needed

❒❒

Check for leaks in condenser and process lines.

Before and during operation, you should inspect the unit and all plumbing lines for leaks. If a leak develops, stop the chiller and repair it.

❒❒

Keep the unit and the area around it clean.

Check for and remove lint, dust or other obstructions on the unit, especially around air intake areas. Keep the floor around the unit dry. If you notice a decrease in efficiency over time, check all heat transfer surfaces of the evaporator and condenser for fouling. See

LEANING

VAPORATORS ANDCONDENSERS

❒❒

Check the process fluid level.

Check the level indicator on the back of the unit to make sure the tank contains an adequate amount of process fluid. Refill as needed. See

EFILLING THETANK

●●

Monthly, or as often as needed.

❒❒

Check the refrigerant charge.

A sight glass located between the condenser and evaporator indicates refrigerant pressure. See

HECKINGREFRIGERANTCHARGE

❒❒

Clean all external surfaces.

Surfaces fouled by dust, dirt, slime, minerals and other contaminants will decrease performance. Wipe all external surfaces, paying particular attention to heat transfer surfaces. Clean the air-cooled condenser surfaces if you find dirt or clogging.

❒❒

Check the water treatment system.

If you use a water treatment system for the water-cooled condenser or the process fluid circuit, maintain the proper chemical levels and follow the recommendations of your water treatment specialist.

PREVENTATIVE MAINTENANCE SCHEDULE

UGH004/0999 microKool Portable Chillers

MAINTENANCE 5-3

●●

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.

●●

Annually (every 12 months)

❒❒

Test and calibrate the unit’s control systems.

The chiller’s Test Mode checks the operation

of displays, control buttons, inputs and outputs. You

can also calibrate the supply and return thermocouples.

See

ERFORMINGSYSTEMTESTS

in this section.

❒❒

Clean all surfaces that come in contact with water.

Minerals and other water contaminants cause heattransfer surface fouling and decrease performance, especially in the water-cooled chiller’s condenser. Clean all water-cooled condenser surfaces. The refrigerant side does not foul because the refrigerant acts as a solvent and operates in a closed filter cycle. See

LEANING

VAPORATORS ANDCONDENSERS

in this section.

WARNING: Improper servicing may result in equipment damage or personal injury.

This equipment should be installed, adjusted, and serviced by qualified technical personnel who are familiar with the construction, operation and potential hazards of this type of equipment.

All wiring, disconnects and fuses should be installed by qualified electrical technicians in accordance with electrical codes in your region.

Only certified refrigerant technicians should recharge the refrigerant used in this system.

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.

To clean the evaporator:

Consult a water treatment specialist for rec-

ommendations on the best chemicals to use to remove contaminants from the evaporator and process fluid circuit surfaces that come in contact with water.

Thoroughly flush cleaning chemicals

from the evaporator and all water-contact surfaces in the process fluid circuit.

For water-cooled condensers:

You should consult a water treatment specialist for recommendations on the best chemicals to use to remove contaminants from the condenser. Thoroughly flush chemicals from the condenser before resuming operation.

For air-cooled condensers:

The air-cooled condensers can accumulate dirt and clog quickly if it is run in a dusty or dirty environment. A clogged condenser increases refrigerant pressure, lowers performance and may cause the fan motors and compressor to overheat.

Clean dirty coil surfaces with a soft brush.

Brush and rinse in the direction of the fins to prevent bending the fins.

Rinse with

cool water or a commercial coil cleaner.

CLEANING EVAPORATORS

microKool Portable Chillers UGH004/0999

5-4 MAINTENANCE

Evaporator

Fluid tank

CLEANING CONDENSERS

Condenser coils

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.

To fill the reservoir:

Locate the fill port at the back of the chiller.

Refill the tank. Monitor

the level using the sight glass on the back of the unit. Because chillers can use pure water or glycol mixtures, make sure you are adding the correct fluid for your application.

REFILLING THE

TANK

UGH004/0999 microKool Portable Chillers

MAINTENANCE 5-5

1 2

IMPORTANT: Do not use deionized water or glycol

mixtures containing additives in a this chiller. Softened water or glycol mixtures with additives, such as automotive fluids, can damage the chiller.

Glycol/water process loop mixtures should use industrial-grade ethylene glycol only. Use a glycol mixture if operating temperatures are below 45° F

See F

REEZEPROTECTIONREQUIREMENTS

in the

ESCRIPTION

section for information on glycol mix-

tures.

Tank

fill port

Tank level

sight glass

microKool Portable Chillers UGH004/0999

5-6 MAINTENANCE

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.

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.

◆ Under low-load conditions, when the hot-gas bypass

valves are operating, bubbles may be visible in the sight glass. This is normal.

If the charge is low, recharge the system.

Contact a certified refrigerant technician to recharge or replace refrigerant. This procedure should be performed only be a qualified technician.

CHECKING REFRIGERANT CHARGE

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.

System tests and calibration should be performed annually.

To enable Test Mode:

Press to shut down the chiller. Disconnect and lock out main power to the unit,

then open the electrical enclosure. Set dip switches 3 and

5 to OFF. Set dip switch 6 to ON. Close the electrical enclosure and restore

power to the unit.

◆ The control displays “tSt.”

◆ The Test Mode LED lights.

Press any button to display the first test menu.

Test mode provides the following menus:

● Key/Display Test

● Input Test

● Output Test

● Calibration

● Total Operating Hours

● Output Monitor Enable/Disable

After performing each test, hold the Setpoint for 3 seconds to index to the next test menu.

The procedure for each test is described on the following pages.

PERFORMING SYSTEM TESTS

UGH004/0999 microKool Portable Chillers

MAINTENANCE 5-7

Stop

1 2

3 4

IMPORTANT: All normal

operating functions are disabled while Test Mode is enabled.To retur n to nor mal operation, you must disable Test Mode.

To disable Test Mode, repeat steps 2 through 5, setting dip switch 6 to OFF instead of ON.

The Key/Display Test verifies the function of displays, LEDs and buttons on the control panel.

Enable Test Mode. 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”.

Press any key to clear all displays. Repeatedly press any key to test displays.

With each key press, a new segment of all six 8-segment LEDs and a select group of LED indicator lights will illuminate.

Exit the test and enter the next test.

Press and hold the Setpoint key for 5 seconds to exit and index to the next test.

KEY/DISPLAY TEST

microKool Portable Chillers UGH004/0999

5-8 MAINTENANCE

1 2

4 5

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).

Connect all inputs to the system. Press any key to display the first test menus. 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”.

Repeatedly press and release any key to test.

With each key press and release, the left display will indicate the number of the input being tested (v1, v2, v3, etc.). The right display indicates either “1” for voltage present or “O” for an absence of voltage.

Only inputs that are actually used by the particular model will be tested.

Exit the test and enter the next test.

Press and hold the Setpoint key for 3 seconds to exit and index to the next test.

INPUT TEST

UGH004/0999 microKool Portable Chillers

MAINTENANCE 5-9

1 2

OUTPUT TEST

microKool Portable Chillers UGH004/0999

5-10 MAINTENANCE

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).

Connect all outputs to the system.

Enable Test Mode. Press any key to display the first test menus. Select the Output Test menu.

Press and hold the Setpoint key for 3 seconds to index to each test menu until the controller displays “oUt”.

Repeatedly press and release any key to test.

With each key press and release, the left display will indicate the number of the output being tested (oS1= OM1; oS2 = OM2; etc.). The right display indicates either “1” for a good output or “O” for a failed output.

Only outputs that are actually used by the particular model will be tested.

Exit the test and enter the next test.

Press and hold the Setpoint key for 3 seconds to exit and index to the next test.

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

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.

Enable Test Mode. Press any key to display the first test menus.

Select the OM Enable/Disable menu.

Press and hold the Setpoint key for 3 seconds to index to each test menu until the controller indicates “oS1” in the actual display and the status of the selected output in the Select display.

Press the Setpoint ▲▲or ▼▼key to change the status.

Each press of the key changes the output status

from ON to OFF or OFF to ON.

Press the Setpoint to select the next output.

Repeat Step 4 to change the status of the output, or press any key to continue indexing through the outputs.

Save changes and exit the output menu.

Press and hold the Select key for 3 seconds to save the changes and exit.

DISABLING OR ENABLING OUTPUT MONITORS

UGH004/0999 microKool Portable Chillers

MAINTENANCE 5-11

1 2

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.

Enable Test Mode.

See

ERFORMINGSYSTEMTESTS

Press any button to display the first test menu.

Select the Calibration Mode menu.

Press and hold the Setpoint key for 3 seconds to index to each test menu until the controller indicates “SC.L” in the Actual display.

Release the Setpoint key.

You are now in calibration mode. Each press and release of this key will exit the current calibration and start the next calibration. The table below lists the calibrations that will be performed.

Using the thermocouple calibrator, apply the appropriate temperature to the control input.

CALIBRATING TEMPERATURE SENSORS

microKool Portable Chillers UGH004/0999

5-12 MAINTENANCE

Special T ools Needed:

❒ ther mocouple calibrator

1 2

SETPOINT ACTUAL

CALIBRATION DISPLAY DISPLAY

Zero Calibrate Supply Sensor 32° F (0° C) SC.L Zero Calibrate Return Sensor 32° F (0° C) rC.L Span Calibrate Supply Sensor 510° F (266° C) SC.H Span Calibrate Return Sensor 510° F (266° C) rC.H

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).

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.

Press Select to start the next calibration.

Pressing and releasing the Select key at the end of a calibration tells the controller to perform the next calibration.

Exit Calibration Mode.

Press and hold the Select key for 3 seconds to exit the Calibration Mode.

You can now proceed to the next test in Test Mode, or disable Test Mode and resume normal operation.

CALIBRATING TEMPERATURE SENSORS

UGH004/0999 microKool Portable Chillers

MAINTENANCE 5-13

NOTE: The original calibration value stored in

EEProm can be restored for the current calibration by pressing the STOP key at any time.

TO DISABLE TEST MODE, complete steps 2

through 5 in P

ERFORMINGSYSTEMTESTS

, setting dip

switch 6 to OFF instead of ON.

You can see the total numbers of operation by accessing the Total Operating Hours Log in Test Mode.

Enable Test Mode. Press any key to display the first test menus.

Index through test menus to the operating log.

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.

Exit the Operating Hours Log.

Press and hold the Select key for 3 seconds to exit and index to the next test.

You can now proceed to another menu in Test Mode, or disable Test Mode and resume normal operation.

LOGGING OPERATING HOURS

microKool Portable Chillers UGH004/0999

5-14 MAINTENANCE

1 2

TO DISABLE TEST MODE, complete steps 2

through 5 in “Performing System Tests”, setting dip switch 6 to OFF instead of ON.

6-1

UGH009/0999 microKool Portable Chillers

●●

Before beginning . . . . . . . . . . . .6-2

●●

A few words of caution . . . . . . .6-2

●●

How to identify the cause

of a problem . . . . . . . . . . . . . . .6-3

IAGNOSTICS

●●

Shut down alarms . . . . . . . . . . .6-4

●●

Warning alarms . . . . . . . . . . . .6-10

●●

System alarms . . . . . . . . . . . . .6-11

●●

Chiller will not power up . . . . .6-12

EPAIR

●●

Checking and replacing fuses .6-13

●●

Resetting overloads . . . . . . . . .6-14

●●

Replacing the pump overload .6-14

●●

Replacing the motherboard . . .6-15

●●

Replacing the compressor

contactor . . . . . . . . . . . . . . . .6-16

●●

Checking the unloader valve . .6-17

●●

Replacing the freezestat . . . . .6-18

TROUBLESHOOTING

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. The diagrams also will note any custom features, such as special wiring, control or plumbing options, not covered in this User Guide.

❏ Verify that you have manuals for other equip-

ment in the process line.

Solving problems may require troubleshooting malfunctions or incorrect operating procedures on other pieces of equipment.

❏ If an alarm is present, note any indicator lights

and messages shown on the control panel.

These indicators will help you discover the cause of the problem more quickly.

The chiller is equipped with many safety devices. Do not remove or defeat them. Improper corrective action can lead to hazardous conditions, and should never be attempted to sustain production.

microKool Portable Chillers UGH004/0999

6-2 TROUBLESHOOTING

BEFORE BEGINNING

A FEW WORDS

CAUTION

WARNING: This machines should be

adjusted and serviced only by qualified technical personnel who are familiar with construction and operation of this type of equipment.

DANGER: Voltage hazard.

Troubleshooting the electrical system of this equipment requires use of precision electronic measuring equipment, and may require access to the electrical enclosure while power is on. Exposure to potentially fatal voltage levels may be unavoidable.These troubleshooting procedures should be performed only by qualified electrical technicians who know how to use this precision electronic equipment and who understand the hazards involved.

UGH004/0999 microKool Portable Chillers

TROUBLESHOOTING 6-3

A status light that turns from green to red indicates an alarm condition.

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.

●●

W arning Alarms: The chiller continues to operate, but

warns of a problem that could lead to a condition that will shut down the unit.

●●

System Errors: The system error codes indicate a non-

recoverable problem with the microprocessor control.

When the chiller control detects a problem, the red Alarm light is activated and the RUN/STOP light changes from green to flashing red.

When an Alarm condition occurs:

Press to silence any optional audible alarm.

◆ The RUN/STOP light changes from flashing red to

steady red.

Note any indicator lights or error messages to

help determine the cause of the problem.

Find the alarm or error code in the diagnostics tables

in the TROUBLESHOOTING section of this manual.

Press to clear the alarm and shut down the chiller to correct the problem.

Press to resume normal operation after the problem is corrected.

HOW TO IDENTIFY

THE

CAUSE OF A

PROBLEM

2 3

Stop

WARNING:

Disconnect and lock out the main power source before opening the chiller or its electrical enclosure for servicing. Disconnect water supply lines as needed.

Run

microKool Portable Chillers UGH004/0999

6-4 TROUBLESHOOTING

SHUT DOWN ALARMS

Alarm

The pump motor overload has tripped. The contact is open.

WARNING:

Only qualified electrical service personnel should examine and correct problems that require opening the unit's electrical enclosure or checking electrical current to diagnose the cause of a problem.

The actual temperature of water supplied to the process is 100° F, or has exceeded 75° F for more than 30 minutes.

Possible cause

Is the correct voltage supplied to the pump motor?

Is the required water flow greater than the pump’s capacity?

Is the motor overload faulty or set incorrectly?

Is the pump working properly?

Is the refrigerant charge low?

Is the unloader valve stuck open?

Did the compressor fail?

Solution

Supply voltage should match the rating on the pump name plate. If voltage is correct, check wiring connections.

❒

Review pump sizing for the application.

❒

Decrease the water flow from the process.

Disconnect the power and open the electrical enclosure. Verify that the overload is set to trip at the proper amperage, which should not exceed the FLA. Manually trip and reset the overload. If the problem continues, replace the overload. See

ESETTING ANDREPLACING

VERLOADS

Replace the pump if supply voltage, wiring and overload settings are correct, but the pump continues to draw excessive current.

See

HECKINGREFRIGERANT

HARGE

. If the charge is low, contact a certified refrigeration technician to recharge.

See

HECKING THEUNLOADER

ALVE

If the valve is stuck open,

contact a certified refrigeration technician to repair.

Check compressor electrical connections. Replace the compressor, if it has failed.

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.

Pump

SAFHi

UGH004/0999 microKool Portable Chiller

TROUBLESHOOTING 6-5

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 automatically shuts down.

◆ The control displays a red LED or alarm code indicating the

source of the problem.

Alarm

Actual temperature of water supplied to the process is below the programmed 10° F safety limit.

The thermocouple in the process return line failed.

The thermocouple in the process supply line failed.

Possible cause

Has the compressor contactor failed closed?

Has the unloader valve failed?

Has the freezestat failed?

Is the thermocouple loose?

Has the thermocouple failed?

Is the thermocouple loose?

Has the thermocouple failed?

Solution

Check phase continuity through the compressor contactor. If the contactor has failed, replace it. See

EPLACING THECOMPRESSOR

ONTACTOR

See

HECKING THEUNLOADER

ALVE

❒ Check the freezestat setting.

It should be set to cut out at 5° F above the freeze point of the process fluid solution.

❒ Check for improper freezes-

tat installation. Verify the freezestat sensor bulb is well insulated and inserted

into the piping well. If the freezestat is properly installed and set, it may have failed See

EPLACING THE

REEZESTAT

Check for a loose thermocouple or loose wire connections to the thermocouple.

Check the thermocouple and replace if necessary.

Check for a loose thermocouple or loose wire connections to the thermocouple.

Check the thermocouple and replace if necessary.

SAFLo

ErrPbr

ErrPbS

microKool Portable Chiller UGH004/0999

6-6 TROUBLESHOOTING

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 automatically shuts down.

◆ The control displays a red LED or alarm code indicating the

source of the problem.

Alarm

The incoming power is out of phase. A leg may have failed or is disconnected.

NOTE: This alarm

is available only on PC-2 models.

Pump fuse.

Compressor fuse.

Unloader valve fuse.

Level Switch fuse.

Possible cause

Is the pump rotating in the wrong direction?

Has one of the main supply wire leads become disconnected?

Has the indicated device blown a fuse?

Is the correct device being used for this fuse location?

Has the motherboard output channel at the designated fuse failed?

Solution

Check pump rotation against the arrow stamped on the pump. If the pump is rotating in the wrong direction, disconnect and lockout the main power source. Open the electrical enclosure, and reverse any two leads on the power connection.

Disconnect power and open the electrical enclosure. Check for loose connections in main supply and on motherboard.

Disconnect and lockout the main power. Open the electrical enclosure. Check for loose wires and incorrectly installed jumpers or terminal blocks associated with the fuse error. Replace the fuse, if necessary. See

HECKING ANDREPLACING

USES

Replace the fuse, then enter Test Mode. Turn off the Output Monitor associated with the fuse location and test outputs. See

ERFORMINGSYSTEMTESTS

and

ISABLING ORENABLING

UTPUTMONITORS

in the

AINTENANCE

section.

Replace the motherboard. See

EPLACING THEMOTHERBOARD

ErrPHS

002FUS

003FUS

004FUS

005FUS

006FUS

UGH004/0999 microKool Portable Chiller

TROUBLESHOOTING 6-7

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

The compressor overload has tripped.

NOTE: This alarm

is available only on models with semihermetic compressor sizes 15 Hp and above.

The Oil Safety input is open.

NOTE: This alarm

can be present only on models with compressor sizes 15 Hp and above.

Possible cause

Is the correct voltage supplied to the motor on the compressor?

Is the overload faulty or set incorrectly?

Is the compressor faulty?

Oil level in the compressor is low, or the input has failed.

Solution

Supply voltage should match the rating on the motor name plate. If voltage is correct, check wiring connections.

Disconnect the power and open the electrical enclosure for the compressor. Verify that the overload is set to trip at the proper amperage, which should not exceed the FLA. Manually trip and reset the overload. If the problem continues, replace the overload.

Replace the compressor if supply voltage, wiring and overload settings are correct, but the pump continues to draw excessive current.

See

ERFORMINGSYSTEMTESTS

and perform an

NPUTTEST

. If the input is OK, call Conair service.

Compressor

Oil Safety Alarm

SHUT DOWN ALARMS

microKool Portable Chillers UGH004/0999

6-8 TROUBLESHOOTING

Alarm

Refrigerant pressure is either too low or too high.

WARNING:

The microKool should be tested and repaired only by qualified technicians equipped with the correct tools and trained in the maintenance and repair of electrical and refrigerant systems used in industrial applications.

Possible cause

Low refrigerant pressure: Is the refrigerant charge

low?

Is the liquid refrigerant line restricted?

High r

efrigerant pressure

Has the water or air flow through the condenser become restricted?

(Continued on next page)

Solution

See

HECKINGREFRIGERANT

HARGE

Check for leaks in the refrigerant circuit. Contact a certified refrigerant technician to repair and recharge the system.

Check for closed valves or a plugged refrigerant line. ❒ Verify that the liquid line

shut-off valve is open.

❒ Verify that the suction valve

at the compressor is open.

❒ Verify that the expansion

valve is working properly.

Check for closed valves and obstructions, contaminants or dirt that may have blocked or restricted condenser efficiency.

All models:

❒ Clean the condenser coils. See

LEANINGCONDENSERS

Air-cooled units:

❒ Remove any obstructions to air

flow at the condenser air inlet and outlet.

❒ Verify that the condenser fans

are working. Confirm proper rotation and check for an electrical overload.

Water-cooled units:

❒ Check for closed valves or

plugged water supply lines.

❒ Verify that the condenser water

supply is working and that incoming water pressure is at least 25 psi.

Refrigerant Pressure

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.

SHUT DOWN ALARMS

UGH004/0999 microKool Portable Chillers

TROUBLESHOOTING 6-9

Alarm

Refrigerant pressure is either too low or too high.

Process fluid in the chiller tank is at the minimum level.

The Freeze Stat Input is open.

Possible cause

High refrigerant pressure Is the temperature of the

condenser supply air or water too high?

Is the refrigerant overcharged?

Is there enough fluid in the tank?

Is there sufficient fluid flow through he evaporator?

Is the freezestat setting too high?

Is the freezestat sensor installed correctly?

Solution

Load conditions may be too high for proper operation.

Air-cooled chillers will not work properly if the ambient air temperature is above 100° F (38° C).

Water-cooled chillers will not work properly if the condenser water supply temperature is above 85° F (29° C). Check cooling tower operation, if a tower supplies the water.

Contact a certified refrigerant technician for servicing.

Check the fluid level by looking at the tank level sight glass at the rear of the chiller. Add fluid, if necessary. See

ILLING

THE

ANK

Check for incorrect pump rotation and closed valves in the process circuit. Verify required GPM rating for the chiller:

(GPM=2.4 x chiller ton capacity)

Setting should be 10° F (5° C) below the operating temperature, and at least 5° F (2° C) above the freezing point of the process fluid.

Check that the sensor bulb is well insulated and inserted completely into piping well.

Low Water Alarm

Refrigerant Pressure

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.

Freeze Stat Alarm

microKool Portable Chillers UGH004/0999

6-10 TROUBLESHOOTING

WARNING ALARMS

Alarm

The actual temperature of fluid supplied to the process is lower than the setpoint deviation limit allows.

The actual temperature of fluid supplied to the process is higher than the setpoint deviation allows.

The SPI communication link has failed.

Possible cause

Is the low deviation temperature set too low?

Is the low deviation temperature set too high?

Has the process fluid stopped flowing between outlet and inlet?

Is the unloader valve stuck open?

Is the unit connected to a host machine?

Are the network address and baud rate correct?

Is something wrong with the cable?

Solution

Increase the low deviation limit setting. The recommended setting is 2° F to 10° F below the process setpoint.

Increase the high deviation limit setting. The recommended setting is 2° F to 10° F above the process setpoint.

Check for plugged pipes and closed valves. Clear any obstructions and open valves.

See

HECKING THEUNLOADER

ALVE

If the chiller is not connected to a host device, set the SPI address to OFF.

❒ Check the network address.

The address may be set to any number from 32 to 254 (a hexadecimal integer between 20 and FE), as long as that number has not been assigned to another machine on the same network.

❒ Make sure the baud rate

(9600, 4800, 2400, or 1200) matches the host machine.

Check the communication cable condition and connections. The cable must conform to SPI standards.

Low Deviation

High Deviation

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.

SPI Communication

UGH004/0999 microKool Portable Chillers

TROUBLESHOOTING 6-11

SYSTEM ALARMS

Alarm

RAM hardware failure.

ROM, checksum failure.

COP failures.

Illegal Opcode.

through

Software cannot write to CPU nonvolatile memory.

Cause

Electrical noise or failed CPU on the motherboard caused system write tests do fail during power up.

The CPU and/or PROM chip (U1 or U2) is not making good contact with its socket, or the PROM chip has failed.

A failed CPU, failed motherboard, software bug or electrical noise caused an internal software error.

The CPU tried to execute an illegal software instruction due to electrical noise or a failed motherboard.

A failed CPU, failed motherboard, software bug or electrical noise caused an internal software error.

The memory has exceeded its usable life or there is a software bug. This error occurs only after changes have been made to nonvolatile memory either through the operator panel or SPI.

Solution

Make sure all connections on the motherboard are solid. Operate unit in a noise free environment. If error persists, contact Conair service.

Make sure the CPU and PROM chips are seated correctly in the sockets. If error persists, contact Conair service.

Cycle power to the unit. If the problem persists, contact Conair service technicians. You may need to replace the motherboard.

Make sure all connections to the motherboard are solid and that the unit is operating in a noise free environment. If error persists, contact Conair service.

Cycle power to the unit. If the problem persists, contact Conair service technicians. You may need to replace the motherboard.

Cycle power to the unit. Contact Conair service if an operating parameter such as the setpoint is not being saved or if this error persists.

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.

001ERR

003ERR

002ERR

004ERR

006ERR

005ERR

015ERR

014ERR

016ERR

microKool Portable Chillers UGH004/0999

6-12 TROUBLESHOOTING

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.

WARNING: Electrical Shock Hazard Disconnect and lockout the main power supply before proceeding.

Symptom

Applying power does not turn on the chiller or light the control panel.

The control panel is lit, but the chiller will not operate when RUN is pressed.

Possible cause

Is power reaching the chiller?

Has the unit blown a fuse?

Is the correct voltage reaching the chiller?

Is the unit in Test Mode?

Solution

❒ Verify that the main power

supply and any customerinstalled electrical disconnect or emergency stop devices are in the ON position.

❒ Verify correct electrical con-

nections between the unit and the control, and between the unit and the power supply. Replace any damaged wires or cables.

Check Fuse 1 on the motherboard and any fuses or breakers associated with customerinstalled disconnect devices. Replace or reset as required. Identify the cause of the ground fault and correct it. See

HECK

ING ANDREPLACINGFUSES

Check the electrical requirements on the unit nameplate. Verify correct main supply voltage to the unit and the secondary voltage supply from the transformer to unit components. Replace the transformer, if necessary.

If the Test Mode LED is lit, you must disable Test Mode on the motherboard before resuming operation. See

ERFORMING

YSTEMTESTS

in the

AINTENANCE

section.

UGH004/0999 microKool Portable Chillers

TROUBLESHOOTING 6-13

CHECKING AND REPLACING FUSES

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.

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:

Disconnect and lockout the main power. Open the electrical enclosure door.

Turn the screw

on the front panel counterclockwise to open.

Replace the fuse. The fuses are located on the mother-

board and are labeled and identified on the orange shield.

Close the electrical enclosure and restart the unit.

If fuses continue to fail:

❒ Verify that the unit is receiving the correct voltage.

Check the voltage, phasing and amperage ratings on the unit’s nameplate.

❒ Verify that the unit’s transformer is operating correctly.

Check for proper voltage (120V 10%) to the voltage sensing device for the fuse location.

❒ Check all wiring referencing the fusing location for

loose connections, damage or improper grounding. Verify that the correct device is being used for this fuse location. See

ISABLING ORENABLINGOUTPUT

ONITORS

in the

AINTENANCE

section.

1 2

3 4

Fuse 1

Control power

Fuse 5

Unloader valve 1

Fuse 4

Unloader valve 2

Fuse 2

Pump

Fuse 3

Compressor

Fuse 6

Level switch

WARNING:

Shock Hazard

Only qualified service personnel familiar with electrical testing and industrial equipment should examine and correct problems that require opening the unit with power on to diagnose the cause of a problem.

432

AUTOSTAR T

HPS/LPS

OPS

FSTAT

HPS/LPS

(-2) CONTROL

OPER PNL CABLE

FSTAT

UNLDR 1/ VENT 2 SOL +

UNLDR 1/ VENT 2 SOL UNLDR 2/ COOL 1 SOL + UNLDR 2/ COOL 1 SOL

1FS/ PURGE/ COMP AUX

LLS/PURGE 3SOL LLS/PURGE 3SOL +

TCPL'S

SUP RET

65432

LLS/WPS

AC IN 4

AUTOSTAR T

AC IN + 3

AC OUT 2

AC OUT + 1

OFF

CONFIGURATION

DIP SWITCH

+ 120 Ohm

+ TR

GND

+ TR

120 Ohm

1 2 3 4 5 6 7 8 1 2 3 4

3 PHASE INPUT

PUMP OL PUMP OL

PMP AUX PMP AUX

1FS/ COMP AUX

PUMPDOWN PUMPDOWN

HEAT/COMP

HEAT/COMP HTS/COMP OL HTS/COMP OL

ALARM

PURGE 4SOL

PURGE 4 SOL +

PUMP PUMP

110V

4 3 2 1

6 5 4 3 2 1

4 3 2 1

NC NO

3 2 1

4 3 2 1

Disconnect and lockout the main power. Open the electrical enclosure door.

Turn the screw

on the front panel counterclockwise to open.

Locate the pump overload module attached

to the pump motor starter.

Disconnect the three power leads from the over-

load module to the pump motor. Note the placement of each lead and label as needed.

Disconnect auxiliary wiring on the overload module.

Remove the overload module.

Loosen the three screws that connect the overload module to the motor contactor. Pull the overload module down to release it from the starter.

Reverse these steps to install the new overload module.

Set the module reset mode to M for manual.

Set the proper FLA trip point.

Do not exceed the FLA for the pump motor.

microKool Portable Chillers UGH004/0999

6-14 TROUBLESHOOTING

RESETTING OVERLOADS

8 9

The pump motor overload is located inside the unit’s electrical enclosure.

Disconnect and lockout the main power. Open the electrical enclosure door.

Turn the

screw on the front panel counterclockwise to open.

Check the overload.

If the yellow button is out, the overload has tripped. Press the blue button to reset the overload. Verify that the overload trip point does not exceed the FLA for the pump.

1 2

MOTOR CON-

Motor overload

REPLACING THE PUMP OVERLOAD

1 2

UGH004/0999 microKool Portable Chillers

TROUBLESHOOTING 6-15

REPLACING THE MOTHERBOARD

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.

Disconnect and lockout the main power supply. Open the electrical enclosure door.

Turn the screw

on the front panel counterclockwise to open.

Mark or label each wire connected to the motherboard.

The orange shield is labeled with the connection information. You must label the wires to ensure they are connected to the correct terminals on the new motherboard.

Disconnect the wires from the motherboard by pulling the terminal blocks up.

Loosen the screws holding the orange shield.

Remove the motherboard and shield

from the

electrical enclosure as a unit.

Remove the motherboard from the shield

and replace with the new motherboard.

Reattach the shield and new motherboard

in the electrical enclosure. Tighten the screws.

Reconnect the terminal blocks and wires to the new board.

Make sure you align the terminal blocks with the correct pins on the board. Push the terminal blocks onto the pins, taking care not to bend any pins.

Set dip switches 7 and 8 to the correct unit type.

Set switch 7 to ON and switch 8 to OFF for chillers.

Program output monitors on the new board.

See

ISABLING ORENABLINGOUTPUTMONITORS

in the

AINTENANCE

section.

2 3

5 6

10 11

432

65432

AC IN 4

AC IN + 3

AC OUT 2

AC OUT + 1

OPS

FSTAT

LLS/WPS

AUTOSTART

FSTAT

HPS/LPS

AUTOSTART

OFF

CONFIGURATION

DIP SWITCH

+ 120 Ohm

1 2 3 4 5 6 7 8 1 2 3 4

AC IN 4

+ TR

AC IN + 3

GND

AC OUT 2

AC OUT + 1

(-2) CONTROL

OPER PNL CABLE

+ TR

120 Ohm

65432

OPS

LLS/WPS AC IN + 3

AUTOSTART AC OUT 2

HPS/LPS

AUTOSTART AC OUT + 1

LLS/WPS

HPS/LPS

LLS/WPS

AUTOSTART

FSTAT AUTOSTART

LLS/WPS AC IN 4

OFF

CONFIGURATION

DIP SWITCH

CONFIGURATION

DIP SWITCH

+ 120 Ohm

+ TR

GND

+ TR

120 Ohm

(-2) CONTROL

+ 120 Ohm

+ TR

OPER PNL CABLE

GND

+ TR

120 Ohm

1 2 3 4 5 6 7 8 1 2 3 4

3 PHASE INPUT

UNLDR 1/ VENT 2 SOL + UNLDR 1/ VENT 2 SOL UNLDR 2/ COOL 1 SOL + UNLDR 2/ COOL 1 SOL

PUMP OL PUMP OL

PMP AUX PMP AUX

1FS/ PURGE/ COMP AUX

1FS/ COMP AUX

PUMPDOWN PUMPDOWN

HEAT/COMP

HEAT/COMP HTS/COMP OL HTS/COMP OL

ALARM

LLS/PURGE 3SOL LLS/PURGE 3SOL +

PURGE 4SOL

PURGE 4 SOL +

TCPL'S

SUP RET

432

OPS

FSTAT

HPS/LPS

UNLDR 2/ VENT 2 SOL + UNLDR 2/ VENT 2 SOL UNLDR 1/ COOL 1 SOL + UNLDR 1/ COOL 1 SOL

LLS/PURGE 3SOL LLS/PURGE 3SOL +

(-2) CONTROL

OPER PNL CABLE

SUP RET

PUMP PUMP

C NC NO

110V

3 PHASE INPUT

1FS/ COMP AUX 1FS/ COMP AUX

PUMPDOWN PUMPDOWN

HEAT/COMP

HEAT/COMP HTS/COMP OL HTS/COMP OL

ALARM

PURGE 4SOL PURGE 4SOL +

TCPL'S

PUMP OL PUMP OL

PMP AUX PMP AUX

SUP RET

4 3 2 1

6 5 4 3 2 1

4 3 2 1

6 5 4 3 2 1

4 3 2 1

3 PHASE INPUT

PUMP PUMP

C NC NO

110V

TCPL'S

4 3 2 1

6 5 4 3 2 1

4 3 2 1

6 5 4 3 2 1

4 3 2 1

The compressor may be located in the compressor electrical enclosure or in the main chiller electrical enclosure, depending on the model of your chiller.

The compressor contactor should be replaced if:

●You have checked the amp draw on each of the three-phase

legs and discovered a voltage imbalance greater than 10%.

● You have checked the continuity and found that ohms at

the coil equal zero.

To replace the compressor contactor:

Disconnect and lockout the main power. Open the electrical enclosure.

Turn the screw on

the front panel counterclockwise to open.

Disconnect the wires from the compressor contactor contactor.

Label the wires to ensure you can

connect them correctly to the new contactor.

Remove and discard the old contactor. Reverse this procedure to install the new con-

tactor.

Make sure the wires are connected correctly.

microKool Portable Chillers UGH004/0999

6-16 TROUBLESHOOTING

1 2

4 5

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.

REPLACING THE COMPRESSOR CONTACTOR

UGH004/0999 microKool Portable Chillers

TROUBLESHOOTING 6-17

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. This increases the temperature within the condenser, simulating an increased load and keeping the compressor running at full capacity.

You can check whether the unloader valve is working properly by observing its behavior while the microKool is running.

Clear any alarms and restart the chiller. Watch for the following:

❒ The unloader valve light should turn on for 2 seconds

when the compressor starts. You should hear the solenoid activate when the unloader valve light turns on.

❒ If the process fluid temperature is below the setpoint,

the unloader valve should stay lit until the temperature of the process fluid exceeds the setpoint.

❒ If the process fluid temperature is above the setpoint,

the unloader valve light should turn off after 2 seconds. You can verify that the unloader valve is inactive by checking the refrigerant line from the solenoid valve to the expansion valve. The line should be cool. If the line is hot all the way to the expansion valve, then the unloader valve is active. The solenoid valve may be leaking, or the unloader valve may be stuck open with power still supplied to the solenoid.

1 2

CHECKING THE UNLOADER VALVE

NOTE:Units with the enhanced PC-2 control have two

unloader valves that work together.

microKool Portable Chillers UGH004/0999

6-18 TROUBLESHOOTING

The freezestat unit is a bulb and capillary thermostat. To replace the unit:

Shut down the chiller and disconnect the process fluid lines.

Disconnect and lockout the power supply. Drain the tank

of all fluid

through the drain valve in the base of the tank.

Locate the freezestat bulb.

The bulb sensor is located on the process piping just after the evaporator.

Remove the insulation around the bulb. Detach the bulb from the process line. Open the chiller electrical enclosure and locate

the freezestat unit. Disconnect freezestat unit wires from their ter-

minals.

Mark the wires so that you can easily reconnect

the new unit to the appropriate terminals..

Loosen the screws holding the freezestat unit to the electrical panel.

Remove the entire freezestat unit.

Threat the bulb and capillary through the raceway.

Reverse the process to install the new unit. Be

sure to insert the bulb sensor completely into the process piping well and replace the insulation around the bulb.

REPLACING THE FREEZESTAT

1 2

WARNING: Electrical shock hazard

Before attempting maintenance of any kind, stop the unit and disconnect and lock out the main power supply.

6 7

Drain valve

Evaporator

10 11

IMS0002/0296 SERVICE INFORMATION

APPENDIX A-1

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:

From outside the United States, call: 814-437-6861

You can commission Conair service personnel to provide onsite service by contacting the Customer Service Department. Standard rates include an on-site hourly rate, with a one-day minimum plus expenses.

If you do have a problem, please complete the following checklist before calling Conair:

❒ Make sure you have all model, serial and parts list

numbers for your particular equipment. Service personnel will need this information to assist you.

❒ Make sure power is supplied to the equipment. ❒ Make sure that all connectors and wires within

and between control systems and related components have been installed correctly.

❒ Check the troubleshooting guide of this manual

for a solution.

❒ Thoroughly examine the instruction manual(s)

for associated equipment, especially controls. Each manual may have its own troubleshooting guide to help you.

❒ Check that the equipment has been operated as

described in this manual.

❒ Check accompanying schematic drawings for

information on special considerations.

BEFORE YOU CALL ...

OW TO CONTACT

CUST OMER SERVICE

Additional manuals and prints for your Conair equipment may be ordered through the Customer Service or Parts Departments for a nominal fee.

WE’RE HERE

HELP

WARRANTY INFORMATION IMS0003/0796

APPENDIX A-2

EQUIPMENT GUARANTEE

PERFORMANCE WARRANTY

WARRANTY LIMITATIONS

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 equipment or as detailed in engineering specifications, provided the equipment is applied, installed, operated and maintained in the recommended manner as outlined in our quotation or specifications.

Should performance not meet warranted levels, Conair at its discretion will exercise one of the following options:

● Inspect the equipment and perform alterations or

adjustments to satisfy performance claims. (Charges for such inspections and corrections will be waived unless failure to meet warranty is due to misapplication, improper installation, poor maintenance practices or improper operation.)

● Replace the original equipment with other Conair

equipment that will meet original performance claims at no extra cost to the customer.

● Refund the invoiced cost to the customer. Credit is

subject to prior notice by the customer at which time a Return Goods Authorization Number (RGA) will be issued by Conair’s Service Department. Returned equipment must be well crated and in proper operating condition, including all parts. Returns must be prepaid.

Purchaser must notify Conair in writing of any claim and provide a customer receipt and other evidence that a claim is being made.

Except for the Equipment Guarantee and Performance Warranty stated above, Conair disclaims all other warranties with respect to the equipment, express or implied, arising by operation of law, course of dealing, usage of trade or otherwise, including but not limited to the implied warranties of merchantability and fitness for a particular purpose.

UGH004/0999 CHILLER SPI COMMANDS

APPENDIX B-1

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.

See the tables on the following pages for the SPI status words and BIT positions for Process Status, Machine 1 Status and Machine 2 status.

For more information on the SPI protocol, you can obtain the SPI Communication Protocol Manual by contacting:

The Society of the Plastics Industry, Inc. 1801 K Street, NW, Suite 600K Washington, D.C. 20006 (202) 974-5200 Fax: (202) 296-7005 www.plasticsindustry.org

SPI COMMANDS SUPPORTED BY

THE

CONAIR

MICRO

OOL

SPI Command Pairs

Portable chillers Device ID: hex 21

Commands Select Poll Echo 0x21 0x21

- Select stores 4 bytes of information at the chiller; Poll retrieves it. 0x21 0x20

Setpoint Process Temperature 0x21 0x21

- Sets and retrieves the process temperature setpoint. 0x31 0x30

Alarm, High Temperature Deviation* 0x21 0x21

- Sets the alarm band temperature; retrieves setpoint + alarm band value.

0x33 0x32

Alarm, Low Temperature Deviation* 0x21 0x21

- Sets the alarm band temperature; retrieves setpoint + alarm band value. 0x35 0x34

Mode, Machine 0x21 0x21

- Start/stops the chiller; acknowledges alarms; retrieves run status

0x49 0x48

Version 0x21

- Retrieves 4 bytes of SPI version information. 0x22

Process Status 0x21

- Retrieves run status and alarm conditions. 0x40

Status, Machine 1 0x21

- Retrieves run status and alarm conditions.

0x42

Status, Machine 2 0x21

- Retrieves run status and alarm conditions. 0x44

Temperature, from Process 0x21

- Retrieves the actual temperature of fluid returning to the chiller. 0x72

* NOTE: Both High and Low Temperature Deviation commands set the same variable. Use only one of these commands to avoid problems.

Status, Process

Poll: 0x21 0x40

SPI STATUS WORD

Word BIT position 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0

EEprom error SET SET

A/D converter error SET SET

CJC Error SET SET

RAM hardware SET SET

ROM checksum SET SET

Probe Failure SET SET

E/M Hi temp safety

Prog. Hi temp safety

Output monitor failure SET SET

Low water pressure SET SET SET

High deviation alarm SET SET SET

Low deviation alarm SET SET SET

Prog. Lo temp safety

Pump overload SET SET

Refrig. Pressure SET SET

Oil Safety SET SET

Compressor overload SET SET

Freeze Stat SET SET

Low water level SET SET

Test Mode

Phase error

NOTES:

The SPI I/O list defines the Processing bit as being cleared if the unit is not processing; otherwise it is SET.

Elsewhere on the chart:

● If a bit is not shown to be SET, it is cleared.

● The System Alarm bit is SET if an alarm is present. It is the logical OR of Process alarm and Machine alarm.

● Processing, System Alarm, Process Alarm and Machine Alar m bits are repeated for Process Status, Machine 1

Status and Machine 2 Status.

SPI STATUS WORDS

CHILLER SPI COMMANDS UGH004/0999

APPENDIX B-2

Open

Reserved

Alarm, Low flow

Reserved

Alarm, Low pressure condition

Alarm, High pressure condition

Alarm, Low temperature deviation

Alarm, High temperature deviation

Alarm, Machine

Alarm, Process

Alarm, System

Processing

UGH004/0999 CHILLER SPI COMMANDS

APPENDIX B-3

Status, Machine 1

Poll: 0x21 0x42

SPI STATUS WORD

Word BIT position 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0

EEprom error SET SET

A/D converter error SET SET

CJC Error SET SET

RAM hardware SET SET

ROM checksum SET SET

Probe Failure

E/M Hi temp safety SET SET SET

Prog. Hi temp safety SET SET SET

Output monitor failure SET SET

Low water pressure SET SET SET

High deviation alarm

Low deviation alarm

Prog. Lo temp safety SET SET SET

Pump overload SET SET

Refrig. Pressure SET SET

Oil Safety SET SET

Compressor overload SET SET

Freeze Stat SET SET

Low water level SET SET

Test Mode

Phase error SET SET SET

NOTES:

The SPI I/O list defines the Processing bit as being cleared if the unit is not processing; otherwise it is SET.

Elsewhere on the chart:

● If a bit is not shown to be SET, it is cleared.

● The System Alarm bit is SET if an alarm is present. It is the logical OR of Process alarm and Machine alarm.

● Processing, System Alarm, Process Alarm and Machine Alarm bits are repeated for Process Status, Machine 1

Status and Machine 2 Status.

SPI STATUS WORDS

Open

Alarm, Phase

Alarm, Low current

Alarm, High current

Alarm, Low volts

Alarm, High volts

Reserved

Alarm, Low pressure safety limit

Alarm, High pressure safety limit

Alarm, Low temperature safety limit

Alarm, High temperature safety limit

Alarm, Machine

Alarm, Process

Alarm, System

Processing

CHILLER SPI COMMANDS UGH004/0999

APPENDIX B-4

Status, Machine 2

Poll: 0x21 0x44

SPI STATUS WORD

Word BIT position 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0

EEprom error SET SET

A/D converter error SET SET

CJC Error SET SET

RAM hardware SET SET

ROM checksum SET SET

Probe Failure SET SET SET

E/M Hi temp safety

Prog. Hi temp safety

Output monitor failure SET SET

Low water pressure

High deviation alarm

Low deviation alarm

Prog. Lo temp safety

Pump overload SET SET

Refrig. Pressure SET SET

Oil Safety SET SET

Compressor overload SET SET

Freeze Stat Low water level SET SET

Test Mode

Phase error

NOTES:

The SPI I/O list defines the Processing bit as being cleared if the unit is not processing; otherwise it is SET.

Elsewhere on the chart:

● If a bit is not shown to be SET, it is cleared.

● The System Alarm bit is SET if an alarm is present. It is the logical OR of Process alarm and Machine alarm.

● Processing, System Alarm, Process Alarm and Machine Alar m bits are repeated for Process Status, Machine 1

Status and Machine 2 Status.

SPI STATUS WORDS

Open

Reserved

Fault, CAL

Fault, Sensor

Alarm, Machine

Alarm, Process

Alarm, System

Processing

PD-1

UGH004/0999 microKool Portable Chillers

●●

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-6

PARTS/DIAGRAMS

PC-1 WIRING DIAGRAM UGH004/0999

PD-2

UGH004/0999 PC-1 CIRCUIT BOARD

PD-3

CONFIGURATION

DIP SWITCH

OFF

4 3 2 1

UNLDR 2/ VENT 2 SOL +

UNLDR 2/ VENT 2 SOL UNLDR 1/ COOL 1 SOL + UNLDR 1/ COOL 1 SOL

PUMP

PUMP PUMP OL PUMP OL

6 5 4 3 2 1

4 3 2 1

6 5 4 3 2 1

4 3 2 1

PMP AUX PMP AUX

1FS/ PURGE/ COMP AUX

1FS/ COMP AUX

NOT USED NOT USED

HEAT/COMP

HEAT/COMP HTS/COMP OL HTS/COMP OL

C NC NO

110V

ALARM

LLS/PURGE 3SOL LLS/PURGE 3SOL +

PURGE 4SOL

PURGE 4 SOL +

3 PHASE INPUT

TCPL'S

SUP RET

AC IN 4

AC IN + 3

AC OUT 2

AC OUT + 1

LLS/WPS

NOT USED

HPS/LPS

OPS

FSTAT

1 2 3 4 5 6 7 8

(-1) CONTROL

OPER PNL CABLE

+ 120 Ohm

+ TR

GND

+ TR

120 Ohm

4 3 2 1

6 5 4 3 2 1

4 3 2 1

1 2 3 4

PC-1

CIRCUIT BOARD

WARNING!

IT IS VERY IMPORTANT

THAT SWITCHES # 7 AND #8 BE SET

TO THE PROPER UNIT TYPE BEFORE

OPERA TING THIS UNIT

CHILLER #7 ON #8 OFF

120 Ohm JUMPER

DB9 (5.9)

DB9 (4.8)

120 Ohm JUMPER

SUPPL Y TCPL

LIQ LINE 3SOL

ALARM

PUMP AUX

COMP

PUMP AUX

(OR 12) COMP

LIQ LINE 3SOL

(OR 12 ) COMP OL

LIQ LINE 3SOL

COMP OL

JUMPER WHEN NOT USED

PUMP

PUMP OL

UNLOADER 2

UNLOADER 1

UNLOADER 2

FROM TRANSFRMR

FROM TRANSFRMR 2

COMP CNTL

OPT. AUTOFILL

1LS

HPS/LPS

OPS

1TAS

HPS/LPS

JUMPER WHEN

NOT USED

PC-2 WIRING DIAGRAM UGH004/0999

PD-4

UGH004/0999 PC-2 CIRCUIT BOARD

PD-5

CONFIGURATION

DIP SWITCH

OFF

4 3 2 1

UNLDR 2/ VENT 2 SOL +

UNLDR 2/ VENT 2 SOL UNLDR 1/ COOL 1 SOL + UNLDR 1/ COOL 1 SOL

PUMP

PUMP PUMP OL PUMP OL

6 5 4 3 2 1

4 3 2 1

6 5 4 3 2 1

4 3 2 1

PMP AUX

PMP AUX 1FS/ COMP AUX 1FS/ COMP AUX

PUMPDOWN PUMPDOWN

HEAT/COMP

HEAT/COMP HTS/COMP OL HTS/COMP OL

C NC NO

110V

ALARM

LLS/PURGE 3SOL LLS/PURGE 3SOL +

PURGE 4SOL PURGE 4SOL +

3 PHASE INPUT

TCPL'S

SUP RET

AC IN 4

AC IN + 3

AC OUT 2

AC OUT + 1

LLS/WPS

AUTOSTART

HPS/LPS

OPS

FSTAT

1 2 3 4 5 6 7 8

(-2) CONTROL

OPER PNL CABLE

+ 120 Ohm

+ TR

GND

+ TR

120 Ohm

4 3 2 1

6 5 4 3 2 1

4 3 2 1

1 2 3 4

PC-2

CIRCUIT BOARD

WARNING!

IT IS VERY IMPORTANT

THAT SWITCHES # 7 AND #8 BE SET

TO THE PROPER UNIT TYPE BEFORE

OPERA TING THIS UNIT

CHILLER #7 ON #8 OFF

120 Ohm JUMPER

DB9 (5.9)

DB9 (4.8)

120 Ohm JUMPER

SUPPL Y TCPL

RETURN TCPL

LIQ LINE 3SOL

ALARM

PUMP AUX

COMP

PUMP AUX

(OR 12) COMP

LIQ LINE 3SOL

(OR 12 ) COMP OL

LIQ LINE 3SOL

COMP OL

JUMPER WHEN NOT USED

LIQ LINE 3SOL

PUMP

PUMP OL

UNLOADER 2

UNLOADER 1

UNLOADER 2

FROM TRANSFRMR

FROM TRANSFRMR 2

COMP CNTL

OPT. AUTOFILL

1LS

1LS4AUTOSTART

AUTOSTART 4

HPS/LPS

OPS

1TAS

HPS/LPS

JUMPER WHEN

NOT USED

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Specifications and Main Features

Frequently Asked Questions

User Manual