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WARNING - Reliance on this Manual Could Result in Severe Bodily Injury or Death!
This manual is out-of-date and is provided only for its technical information, data and capacities. Portions of this manual
detailing procedures or precautions in the operation, inspection, maintenance and repair of the product forming the subject
matter of this manual may be inadequate, inaccurate, and/or incomplete and cannot be used, followed, or relied upon.
Contact Conair at info@conairgroup.com 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than those contained in this out-of-date manual.
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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.
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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
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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
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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
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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
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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.
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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
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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
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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
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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
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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
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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
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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)
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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
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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
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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.
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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
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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
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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
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.
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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
1
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.
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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.
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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.
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.
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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.
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
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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.
1
2
3
4
6
5
4
7
8
12
3