Conair MPA-7.5, MPW-7.5, MPW-5, MPW-3, MPW-2 User Manual

WARNING - Reliance on this Manual Could Result in Severe Bodily Injury or Death!

This manual is out-of-date and is provided only for its technical information, data and capacities. Portions of this manual
detailing procedures or precautions in the operation, inspection, maintenance and repair of the product forming the subject
matter of this manual may be inadequate, inaccurate, and/or incomplete and cannot be used, followed, or relied upon.
Contact Conair at [e-mail] or 1-800-654-6661 for more current information, warnings, and materials about
more recent product manuals containing warnings, information, precautions, and procedures that may be more adequate
than those contained in this out-of-date manual.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.

Copyright 1999

All rights reserved

THE CONAIR GROUP, INC.

UGH004/0999 microKool Portable Chillers

TABLE OF
CONTENTS

I

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

i

TABLEOF
CONTENTS

M

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

ii

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

1

◆
❒

●

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 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.

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. Every 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 run 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 MP A-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 r un full r un 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

0

-10

-20

-30

-40

-50

-60
2004060

80

100

40
30
20
10

0

-10

-20

-30

-40

-50

-60

-70

-80
2004060

80

100

Freeze Protection Requirements

by Unit Set Temperature

Freezing Points of Aqueous

Ethylene Glycol Solutions

Ethylene Glycol, % by weight

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.

1

2

3

4

5

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

1

2

Process machine

Chiller

Alternate
locations

3

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

1

2

3

4

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

F

REEZEPROTECTION

R

EQUIREMENTS

.

Tank

fill port

Condenser

water in

From

Process

Condenser

water out

Condenser water
connections on
MPW models only

To

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.

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2

3
4

5

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 wiring,
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 electr ical
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

T

ROUBLESHOOTING

section if it did not.

TESTING THE INSTALLATION

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2

3

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

1

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)

2

NOTE:

If you enabled passcode protection, you must enter

the passcode to change this parameter. See E

NABLING AND

D

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

S

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.

12

3

4

5

6

7

8

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

8

†

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.

12

3

4

5

6

7

8

1

2
3

4

INSTALLATION 3-9

WARNING: Electric shock hazard

This equipment is powered by high voltage. Always
disconnect and lock out the main power source
before opening the unit or the electrical enclosure to
modify factory settings. Failure to disconnect and
lock out the main power source can result in severe
personal injury.

6

5

7

8

12

3

4

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

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.

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2

3

4

5

6

6

5

4

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8

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