Conair UGH016-0500 User Manual
P ortable Chiller s
Series 1 W ater-Cooled (W1) and
Air-Cooled Models (A1) with TIC Control
Instant Access
Parts and Service
(800) 458-1960
(814) 437-6861
www.conairnet.com
The Conair Group, Inc.
One Conair Drive
Pittsburgh, PA 15202
Phone: (412) 312-6000
Fax:(412) 312-6227
UGH016/0500
Installation
Operation
Maintenance
Troubleshooting
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: UGH016/0500
Serial number(s):
Model number(s):
Power specifications:
Amps
Volts
Phase
Cycle
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 2000
All rights reserved
THE CONAIR GR OUP, INC.
UGH016/0500 Series 1 Portable Chillers, TIC Control
TABLE OF
CONTENTS
I
NTRODUCTION . . . . . . . . . . . . . . . . . . .1-1
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
DESCRIPTION . . . . . . . . . . . . . . . . . . . .2-1
What is the Portable Chiller? . . . . . . . . . . . . . . . . . . . . . . .2-2
Typical Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-3
Limitations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-3
How it Works: Water-cooled Portable Chiller . . . . . . . . . .2-4
How it Works: Air-cooled Portable Chiller . . . . . . . . . . . .2-6
Portable Chiller Features . . . . . . . . . . . . . . . . . . . . . . . . . .2-8
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-10
Pump Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-12
INSTALLATION . . . . . . . . . . . . . . . . . . . .3-1
Unpacking the Boxes . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2
Warnings and Cautions . . . . . . . . . . . . . . . . . . . . . . . . . . .3-3
Preparing for Installation . . . . . . . . . . . . . . . . . . . . . . . . . .3-4
Making Process Plumbing Connections . . . . . . . . . . . . . . .3-5
Filling the Chiller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-6
Checking Refrigerant Charge . . . . . . . . . . . . . . . . . . . . . . .3-8
Connecting the Main Power Source . . . . . . . . . . . . . . . . . .3-9
Checking Electrical Connections . . . . . . . . . . . . . . . . . . .3-10
Initially Starting the Chiller . . . . . . . . . . . . . . . . . . . . . . .3-11
Stopping the Chiller . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-12
OPERATION . . . . . . . . . . . . . . . . . . . . . .4-1
TIC Control Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2
Before Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-3
Starting/Stopping the Chiller . . . . . . . . . . . . . . . . . . . . . . .4-4
Changing Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-5
Changing the Setpoint Temperature . . . . . . . . . . . . . . . . . .4-6
Changing Temperature Scale . . . . . . . . . . . . . . . . . . . . . . .4-7
Changing to Auto Tune Mode . . . . . . . . . . . . . . . . . . . . . .4-7
Setting the To Process Low Limit . . . . . . . . . . . . . . . . . . .4-8
i
Series 1 Portable Chillers, TIC Control UGH016/0500
T
ABLE OF
C
ONTENTS
M
AINTENANCE . . . . . . . . . . . . . . . . . . . .5-1
Maintenance Features . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-2
Warnings and Cautions . . . . . . . . . . . . . . . . . . . . . . . . . . .5-3
Preventative Maintenance Schedule . . . . . . . . . . . . . . . . . .5-4
Checking the Refrigerant Charge . . . . . . . . . . . . . . . . . . . .5-6
Cleaning the Evaporator or Water-cooled Condenser . . . . .5-7
Cleaning the Air-cooled Condenser . . . . . . . . . . . . . . . . . .5-8
Checking Electrical Connections . . . . . . . . . . . . . . . . . . . .5-9
Checking Reservoir Level . . . . . . . . . . . . . . . . . . . . . . . .5-10
TROUBLESHOOTING . . . . . . . . . . . . . . . .6-1
Before Beginning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-2
A Few Words of Caution . . . . . . . . . . . . . . . . . . . . . . . . . .6-2
Identifying the Cause of a Problem . . . . . . . . . . . . . . . . . .6-3
Answering an Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-4
Control Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-5
Mechanical Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . .6-7
Checking and Replacing Switches . . . . . . . . . . . . . . . . . .6-15
Replacing the Contactor . . . . . . . . . . . . . . . . . . . . . . . . . .6-16
Checking and Replacing the RTD . . . . . . . . . . . . . . . . . .6-17
Replacing the Temperature Controller (TIC) . . . . . . . . . .6-18
Replacing Overload Modules . . . . . . . . . . . . . . . . . . . . . .6-19
Replacing Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-20
Removing Pump Components . . . . . . . . . . . . . . . . . . . . .5-21
Checking the Pressure Switches . . . . . . . . . . . . . . . . . . . .6-22
A
PPENDIX . . . . . . . . . . . . . . . . . . . . . .A-1
Customer Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-2
Maintenance Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-1
Pressure Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-1
Control Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-1
PARTS AND DIAGRAMS . . . . . . . . . . . .P/D-1
ii
1-1
Series 1 Portable Chillers, TIC Control UGH016/0500
●●
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
Series 1 Portable Chillers, TIC Control UGH016/0500
1-2
INTRODUCTION
This User Guide describes Conair’s Series 1 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 sources, intended use 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
O
RGANIZED
1
◆
❒
●
YOUR
RESPONSIBILITY
ASAUSER
UGH016/0500 Series 1 Portable Chillers, TIC Control
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: Improper installation, operation, or servicing may result in equipment damage or personal injury.
This equipment should only be installed, adjusted, and serviced by qualified technical personnel who are familiar with the construction, operation, and potential hazards of this type of
machine.
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. Do not operate
the equipment at power levels other than what
is specified on the machine serial tag and data
plate.
WARNING: Electrical hazard
Before performing any work on this item, disconnect and lock out electrical power sources to
prevent injury from unexpected energization or
startup.
CAUTION: Hot Surfaces
Always protect yourself from hot surfaces when
working on the Portable Chiller, especially when
working on or around the compressor and condenser.These devices can reach up to 160 °F
(71 °C). Allow these devices to cool before performing any maintenance or troubleshooting.
CAUTION:Ventilation hazard
The unit requires a clean and well ventilated
operating environment. Do not place anything
on top of the unit while operating. Units with
fans require unrestricted outlet air flow.
Water-cooled units require a minimum of one
foot clearance around the perimeter for serviceability. Air-cooled units require a minimum of two
feet clearance around the perimeter for serviceability and proper air flow.
2-1
Series 1 Portable Chillers, TIC Control UGH016/0500
●●
What is the Portable Chiller? . . .2-2
●●
Typical Applications . . . . . . . . . .2-3
●●
Limitations . . . . . . . . . . . . . . . . .2-3
●●
How it Works:Water-cooled
Portable Chiller . . . . . . . . . . . .2-4
●●
How it Works: Air-cooled
Portable Chiller . . . . . . . . . . . .2-6
●●
Portable Chiller Features . . . . . .2-8
●●
Specifications . . . . . . . . . . . . .2-10
●●
Pump Curves . . . . . . . . . . . . . .2-12
DESCRIPTION
The Conair Series 1 Portable Chillers provide self-contained
sources of chilled water and are available in either water- or
air-cooled models, ranging in sizes from 3.5 Hp to 40 Hp
(approximate capacities of 3.5 tons of refrigeration to 40 tons
of refrigeration). Pump selections are available to match most
process flow and pressure requirements.
The normal temperature range of discharge chilled water is
20 °F to 70 °F. For applications requiring 40 °F and lower
mix glycol with the water to the correct percentage.
The Air-cooled Portable Chiller A1 Models and Water-cooled
Portable Chiller W1 Models are designed to provide chilled
water for industrial applications requiring 24-hour-a-day performance. Units are totally self-contained for easy, economical
installation. All parts wetted by the process are non-ferrous.
To operate, simply connect the power source, process piping
and fill with water or ethylene or propylene glycol (but not
automotive antifreeze).
These chillers are ideal for machine-side cooling to maintain
process temperatures in an injection molding machine or
extruder and wherever you need a small, moveable cooling
unit. Nominal capacities range from 1.44 to 14.68 tons for the
water-cooled models and from 1.18 to 10.95 tons for the aircooled models. Capacities are based on standard pump sizes
and delivering 50 °F water.
Operation of these units differ only in the medium used to
remove heat from the refrigerant in the condensers. Watercooled models use 85 °F (29 °C) or lower cooling water from
a tower, well, or city service; air-cooled models use 95 °F
(35 °C) maximum ambient air.
Choose water-cooled portable chillers where tower water or
another inexpensive water source is available. Choose aircooled models for maximum portability of the unit. Watercooled models are equipped with brazed plate or tube-in-tube
condensers. Air-cooled models use aluminum-fin, copper-tube
condensers.
All standard voltages are available.
W
HAT IS THE
PORTABLE
CHILLER?
Series 1 Portable Chillers, TIC Control UGH016/0500
2-2
DESCRIPTION
The Conair A1 and W1 Portable Chillers can be used anywhere a reliable source of process cooling water - with stable
temperature control - is required.
These portable chillers are available for cooling injection
molding, blow molding, thermoforming, extrusion, air compressors, metal plating, anodizing, degreasing, heatset/web
offset printing presses, and dryer after-coolers.
Roll the air-cooled condenser models next to the heat source
connect it and plug it in. They can operate almost anywhere.
The water-cooled condenser models require a source of condenser water. Normally used in conjunction with a recirculating evaporative cooling tower system, the units have slightly
better operating energy efficiencies.
T
YPICAL
APPLICATIONS
UGH016/0500 Series 1 Portable Chillers, TIC Control
DESCRIPTION 2-3
L
IMITATIONS
Conair Series 1 Portable Chillers are designed to provide
chilled water for industrial applications requiring 24-hour-aday performance. Units are self-contained and easy to install
and maintain. Choose the Conair Series 1 Portable Chillers
based on the cooling load and the capacity of the unit. Pick
your Conair Series 1 Portable Chillers based on:
● Cooling load
Choose a portable chiller that has 20% more capacity than
the process load.
● Location
Choose a water-cooled model if the unit will be located in
an air-conditioned area. Choose the water-cooled model if
a source of condenser water is readily available (i.e. cooling tower water). Do not locate the portable chiller outside unless the unit is specially modified.
● Temperature
The portable chiller needs to provide a cooling temperature less than 70 °F (21°C).
Use this information as a general guide. Consult your Conair
representative for assistance when choosing a Conair Portable
Chiller.
H
OW IT WORKS:
W
ATER-COOLED
PORTABLE
CHILLER
Series 1 Portable Chillers, TIC Control UGH016/0500
2-4
DESCRIPTION
Pump draws water
from pump reservoir
and moves it through the
strainer and flow switch to
the evaporator.
2
Fluid is chilled in the
evaporator and exits
through the to Process
valve and tube, returning to
the process.
3
Hot fluid from the
process enters the
chiller through the From
Process valve into the
pump reservoir.
1
Process circulation
UGH016/0500 Series 1 Portable Chillers, TIC Control
DESCRIPTION 2-5
The evaporator extracts heat
from the process fluid, causing the refrigerant to vaporize
(evaporate) into a gas.
1
Vaporized refrigerant
travels from evaporator to the compressor,
where the low pressure
vapor is compressed into
a high pressure vapor.
2
The liquid refrigerant
leaves the accumulator, passing through the
thermal expansion valve,
where it expands and
cools.
4
H
OW IT WORKS:
W
ATER-COOLED
CONT’D
Refrigerant circulation
The high pressure vapor travels from
the compressor through the coiled
condenser (where it is condensed into a
liquid) and is stored in the accumulator.
3
Cooled refrigerant is metered
back into the exaporator for
the cycle to begin again.
5
H
OW IT WORKS:
A
IR-COOLED
PORTABLE
CHILLER
Series 1 Portable Chillers, TIC Control UGH016/0500
2-6
DESCRIPTION
Process circulation
Fluid is chilled in the
evaporator and exits
through the To Process
valve and tube, returning to
the process.
3
Hot fluid from the
process enters the
chiller through the From
Process valve into the
pump reservoir.
1
Pump draws fluid
from pump reservoir
and moves it through the
strainer and flow switch to
the evaporator.
2
UGH016/0500 Series 1 Portable Chillers, TIC Control
DESCRIPTION 2-7
H
OW IT WORKS:
A
IR-COOLED
PORTABLE
CHILLER
Refrigerant circulation
The evaporator extracts heat
from the process fluid, causing the refrigerant to vaporize
(evaporate) into a gas.
1
Vaporized refrigerant
travels from evaporator to the compressor,
where the low pressure
vapor is compressed into
a high pressure vapor.
2
The liquid refrigerant
leaves the accumulator,
passing through the thermal expansion valve,
where it expands and
cools.
4
The high pressure vapor
travels from the compressor
through the condenser (where
fans cool vapor into a liquid)
and liquid is stored in the
accumulator.
3
Cooled refrigerant is metered
back into the exaporator for
the cycle to begin again.
5
Series 1 Portable Chillers, TIC Control UGH016/0500
2-8
DESCRIPTION
P
ORTABLE
CHILLER
FEATURES
Receiver
stores the liquid refrigerant.
Filter dryer
cleans and dries the refrigerant.
From Process valve
Relief valve
acts as a safety
device for refrigerant pressure.
Condenser
compresses the
refrigerant from a
high pressure vapor
into a high pressure
liquid.
Liquid line solenoid
valve
pumps down refrigerant
to the receiver.
Temperature transmitter electrical box
transmits temperature
signals to the control
Process pump
circulates fluid through
the chiller.
Compressor
compresses the refrigerant from a low pressure vapor into a high
pressure vapor.
Hot Gas Bypass valve
balances the load on the
chiller to meet the needs of
the process.
To Process valve
TX valve
regulates refrigerant flow
Evaporator
cools the To Process fluid
Pump reservoir
stores process fluid.View fluid
level on water level gauge
Options include:
● 60 Hz process pump
1 1/2 Hp for W1-1.5, W1-2
2 Hp for W1-3, W1-4
3 Hp for W1-5, W1-7.5, W1-10, W1-15
● To Process and From Process valves
● Process bypass line and valve
● No reservoir/pump
● No reservoir
● Auto fill reservoir
● Condenser water differential pressure switch (W1-7.5 to
W1-15 only)
● Visual alarm
● Audible alarm
● Remote/redundant hand control with 30 ft. cable
● Remote/redundant hand control with 50 ft. cable
● UL labeled controls
Water-cooled Models
UGH016/0500 Series 1 Portable Chillers, TIC Control
DESCRIPTION 2-9
Air-cooled Models
P
ORTABLE
CHILLER
FEATURES
Fans
circulate air across the condenser to cool refrigerant
Receiver
stores the liquid refrigerant.
Filter dryer
cleans and dries the refrigerant.
From Process valve
Hot Gas Bypass valve
balances the load on the
chiller to meet the needs of
the process.
To Process valve
Evaporator
cools the To Process fluid
Liquid line solenoid
valve
pumps down refrigerant
to the receiver.
Temperature transmitter electrical box
transmits temperature
signals to the control
Process pump
circulates fluid through
the chiller.
Compressor
compresses the refrigerant from a low pressure
vapor into a high pressure vapor.
TX valve
regulates refrigerant flow
Condenser
compresses the refrigerant
from a high pressure vapor
into a high pressure liquid.
Options include:
● 60 Hz process pump
1 1/2 Hp for A1-1.5,A1-2.25
2 Hp for A1-3.25, A1-4
3 Hp for A1-5,A1-7.5, A1-10, A1-13
● To Process and From Process valves
● Process bypass line and valve
● Condenser air filters
● No reservoir/pump
● No reservoir
● Auto fill reservoir
● Visual alarm
● Audible alarm
● Remote/redundant hand control with 30 ft. cable
● Remote/redundant hand control with 50 ft. cable
● UL labeled controls
Pump reservoir
stores process fluid.View fluid
level on water level gauge
Series 1 Portable Chillers, TIC Control UGH016/0500
2-10
DESCRIPTION
Water-cooled Models
S
PECIFICATIONS
front
side
back
B
A
C
D
E
F
10 {254}
9 {229}
10.5 {267}
5.5 {140}
MODEL W1-1.5 W1-2 W1-3 W1-4 W1-5 W1-7.5 W1-10 W1-15
Performance characteristics
Capacity✝tons 1.44 1.93 3.23 4.44 5.00 7.09 10.22 14.68
Compressor Hp {kW} 1.5 {1.1} 2 {1.5} 3 {2.2} 4 {3} 5 {3.7} 7.5 {5.6} 10 {7.5} 15 {11}
Pump Hp {kW}
60 Hz 0.75 {0.6} 0.75 {0.6} 1 {.8} 1 {.8} 1.5 {1.1} 1.5 {1.1} 1.5 {1.1} 2 {1.5}
50 Hz 1.5 {1.1} 1.5 {1.1} 1.5 {1.1} 2 {1.5} 2 {1.5} 2 {1.5} 2 {1.5} 2 {1.5}
Chilled water flow‡gpm {lpm} 6.9 {25.1} 4.6 {17.4} 7.8 {29.5} 10.7 {40.5} 12.0 {45.4} 17.0 {64.3} 24.5 {92.7} 35.2 {133.2}
Chilled water pressure§psi {bar} 27.8 {1.9} 29.9 {2.1} 32.9 {2.3} 31.8 {2.2} 41.6 {2.9} 34.8 {2.4} 29.3 {2.0} 32.3 {2.2}
Reservoir capacity gal {l} 8.0 {30.3} 15 {57} 15 {57} 15 {57} 15 {57} 25 {95} 25 {95} 25 {95}
Condenser water flow gpm {lpm} 5.0 {18.9} 6.4 {24.2} 10.3 {39.0} 14.2 {53.7} 16.7 {63.2} 24.1 {91.2} 31.7 {120} 45.4 {172}
Dimensions in {mm}
A-Height 49 {1245} 49 {1245} 61 {1549}
B-Width 34 {864} 34 {864} 34 {864}
C-Length 39.5 {1003} 45.5 {1156} 55 {1397}
D-Height to condenser out 37 {940} 38.5 {978} 38.5 {978} 38.5 {978} 38 {965} 41.3 {1049} 41.3 {1049 41.3 {1049}
E-Height to condenser in 31 {787} 32.5 {826} 32.5 {826} 32.5 {826} 32 {813} 35 {889} 35 {889} 35 {889}
F-Distance to valve 4 {102} 4.5 {114}
Weight lb {kg}
Installed
420 {190} 585 {265} 585 {265} 840 {381} 840 {381} 1080 {490} 1090 {494} 1095 {497}
Shipped 550 {249}
755 {342} 755 {342} 1010 {458} 1010 {458} 1250 {567} 1260 {572} 1265 {574}
Utility requirements
Process connections NPT in 1 1.5
Condenser water NPT in 1 1.5
Power consumption amps run full run full run full run full run full run full run full run full
230V/3 phase/60hz* 9.5 15.3 10.2 15.6 15.1 24.4 18.7 29.4 22.5 36.3 29.2 44.7 35.0 56.0 44.8 79.0
220V/3 phase/50hz 13.1 19.1 13.8 19.4 17.8 27.5 22.5 33.6 24.3 38.6 31.3 47.4 37.4 59.1 46.8 82.1
460V/3 phase/60hz* 4.5 6.9 4.9 7.1 7.3 11.1 9.1 13.3 10.9 16.4 14.2 20.2 17.1 25.3 22.0 35.7
575V/3 phase/60hz* 3.6 5.5 3.9 5.7 5.8 8.9 7.3 10.7 8.7 13.1 11.4 16.2 13.7 20.2 17.6 28.5
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, for the 60 Hz units.For the 50 Hz units, multiply the capacity by 0.8 Consult factory for other conditions. Capacity ratings
are (+-) 5% based on compressor manufacturer’s ratings and are subject to change without notice.
‡
Based on 50° F (10 °C) water temperature leaving the chiller and 60 °F (16 °C) water temperature returning to the chiller (except W1-1.5
which has 55 °F (13 °C) water temperature returning to the chiller).
§
Pressure at pump discharge. See Pressure Tables in the Appendix for Evaporator and Condenser pressure drops.
* Optional
Air-cooled Models
S
PECIFICATIONS
A
B
C
front
side
back
10 {254}
9 {229}
10.5 {267}
5.5 {140}
UGH016/0500 Series 1 Portable Chillers, TIC Control
D
ESCRIPTION 2-11
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 for
the 60 Hz units. For the 50 Hz units, multiply the capacity by 0.8. Consult factory for other conditions. Capacity ratings are (+-) 5% based on
compressor manufacturer’s ratings and are subject to change without notice.
‡
Based on 50 °F (10 °C) water temperature leaving the chiller and 60 °F (16 °C) water temperature returning to the chiller (except A1-1.5 and
A1-2.25 which have 55 °F (13 °C) water temperature returning to the chiller).
§
Pressure at pump discharge. See Pressure Tables in the Appendix for Evaporator and Condenser pressure drops.
* Optional
MODEL A1-1.5 A1-2.25 A1-3.25 A1-4 A1-5 A1-7.5 A1-10 A1-13
Performance characteristics
Capacity✝, tons 1.18 1.79 2.77 3.62 4.27 6.06 8.75 10.95
Compressor Hp{kW} 1.5 {1.1} 2.25 {1.7} 3.25 {2.4} 4 {3} 5 {3.7} 7.5 {5.6} 10 {7.5} 13 {}
Pump Hp {kW}
60 Hz 0.75 {0.6} 0.75 {0.6} 1 {.8} 1 {.8} 1.5 {1.1} 1.5 {1.1} 1.5 {1.1} 2 {1.5}
50 Hz 1.5 {1.1} 1.5 {1.1} 1.5 {1.1} 2 {1.5} 2 {1.5} 2 {1.5} 2 {1.5} 2 {1.5}
Chilled water flow‡, gpm {lpm} 5.7 {21.6} 8.6 {32.6} 6.7 {25.4} 8.7 {32.9} 10.2 {38.6} 14.5 {54.9} 21.0 {79.5} 26.3 {99.6}
Chilled water pressure§, psi {bar} 29.6 {2.0} 28.5 {2.0} 35.9 {2.5} 33.9 {2.3} 42.4 {2.9} 36.9 {2.5} 31.6 {2.2} 36.1 {2.5}
Reservoir capacity , gal {l} 8.8 {33.3} 15 {57} 15 {57} 15 {57} 15 {57} 25 {95} 25 {95} 25 {95}
Condenser fans 1 2 2 2 2 2 2 4
Condenser fan power Hp {kW} 0.17 {0.13} 0.17 {0.13} 0.17 {0.13} 0.25 {0.19} 0.25 {0.19} 0.5 {0.4} 0.5 {0.4} 0.5 {0.4}
Condenser air flow 1050 1704 2420 4237 4237 5300 5300 9800
ft3/min {liters/min} {29,732} {48,250} {68,525} {119,975} {119,975} {150,075} {150,075} {277,505}
Dimensions in {mm}
A-Height 49 {1245} 49 {1245} 53.5 {1359} 71 {1524} 75 {1905}
B-Width 34 {864} 34 {864} 34 {864} 34 {864} 34 {864}
C-Length 39.5 {1003} 45.5 {1156} 55 {1397} 55 {1397} 55 {1397}
Weight lb {kg}
Installed
610 {277} 830 {376} 830 {376} 1030 {467} 1030 {467} 1230 {558} 1230 {558} 1440
{653}
Shipped 750 {340}
1000 {454} 1000 {454} 1200 {544} 1200 {544} 1400 {635} 1600 {726} 1800 {816}
Utility requirements
Process connections in 1 1.5
Power consumption amps run full run full run full run full run full run full run full run full
230V/3 phase/60hz* 11.0 19.6 13.3 20.8 18.6 32.2 23.7 33.3 27.8 40.1 38.6 47.2 47.2 62.7 57.4 76.9
220V/3 phase/50hz* 14.7 23.6 17.1 24.8 21.5 35.5 27.7 37.6 29.9 42.6 41.2 50.0 50.2 66.1 60.0 79.9
460V/3 phase/60hz 5.3 8.9 6.5 9.4 9.0 14.6 11.6 15.1 13.5 18.2 18.9 21.4 23.2 28.4 28.3 34.8
400v/3 phase/50hz* 7.7 11.8 9.0 12.4 11.4 17.8 14.8 18.8 16.0 21.3 22.2 25.0 27.2 33.0 32.6 40.0
575V/3 phase/60hz* 4.2 7.1 5.2 7.5 7.2 11.7 9.3 12.1 10.8 14.5 15.1 17.1 18.6 22.7 22.6 27.8
Series 1 Portable Chillers, TIC Control UGH016/0500
2-12
DESCRIPTION
P
UMP CURVES
Flow Rate (gpm)
Pressure (psi)
60 HZ PUMP PERFORMANCE CURVES
50 HZ PUMP PERFORMANCE CURVES
Pressure (psi)
Flow Rate (gpm)
3-1
Series 1 Portable Chillers, TIC Control UGH016/0500
●●
Unpacking the Boxes . . . . . . . . . .3-2
●●
Warnings and Cautions . . . . . . . . .3-3
●●
Preparing for Installation . . . . . . .3-4
●●
Making Process Plumbing
Connections . . . . . . . . . . . . . . . .3-5
●●
Filling the Chiller . . . . . . . . . . . . . .3-6
●●
Checking Refrigerant Charge . . . .3-8
●●
Connecting the Main
Power Source . . . . . . . . . . . . . . .3-9
●●
Checking Electrical
Connections . . . . . . . . . . . . . . .3-10
●●
Initially Starting the Chiller . . . . .3-11
●●
Stopping the Chiller . . . . . . . . . .3-12
INSTALLATION
The portable chiller comes fully assembled in a single crate.
U
NPACKING THE
BOXES
Series 1 Portable Chillers, TIC Control UGH016/0500
3-2
INSTALLATION
CAUTION: Lifting hazard
The Series 1 Portable Chillers are designed to
easily roll on casters. If, for some reason you
need to lift the chiller, take all precautions to
avoid personal injury or damage to the chiller.
Lift the chiller using a forklift or hoist with straps
that have peen positioned at the chillers’center
of gravity. Do not try to lift the unit manually.
Carefully uncrate the chiller
and its components.
Remove all packing material, protective paper,
tape, and plastic. compare contents to the shipping papers
to ensure that you have all the parts.
Carefully inspect all components to make sure
no damage occurred during shipping. If any damage is
found, notify the shipping agent immediately. Check all
wire terminal connections, bolts, and any other electrical
connections, which may have come loose during shipping. Check for pinched wires and kinked hoses.
Record serial numbers and specifications
in the blanks provided on the back of the User Guide’s
title page. This information will be helpful if you ever
need service or parts.
1
2
3
3
WARNING: Improper installation, operation, or servicing may result in equipment damage or personal injury.
This equipment should only be installed, adjusted, and serviced by qualified technical personnel who are familiar with the construction, operation, and potential hazards of this type of
machine.
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. Do not operate
the equipment at power levels other than what
is specified on the machine serial tag and data
plate.
CAUTION: Hot Surfaces
Always protect yourself from hot surfaces when
working on the Portable Chiller, especially when
working on or around the compressor and condenser.These devices can reach up to 160 °F
(71 °C). Allow these devices to cool before performing any maintenance or troubleshooting.
CAUTION:Ventilation hazard
The unit requires a clean and well ventilated
operating environment. Do not place anything
on top of the unit while operating. Units with
fans require unrestricted outlet air flow.
Water-cooled units require a minimum of one
foot clearance around the perimeter for serviceability. Air-cooled units require a minimum of two
feet clearance around the perimeter for serviceability and proper air flow.
W
ARNINGS AND
CAUTIONS
UGH016/0500 Series 1 Portable Chillers, TIC Control
INSTALLATION 3-3
P
REPARING FOR
INSTALLATION
Series 1 Portable Chillers, TIC Control UGH016/0500
3-4
INSTALLATION
Plan the location for the chiller and prepare the area properly.
Position the Chiller as close to the process machine as possi-
ble. Place the chiller in position near the process machine so
that fluid lines can be connected from the process machine to
the chiller and back.
Make sure the area where the chiller is installed has:
● A grounded power source.
Check the chiller’s serial tag for the correct amps, voltage, phase, and cycle. All wiring should be completed by
qualified personnel and comply with your region’s electrical codes.
● Clearance for safe operation and maintenance.
Make sure there is two feet clearance around the chiller
for proper operation, maintenance, and servicing. After
positioning, lock casters to prevent chiller from moving.
● Available water source.
If installing a water-cooled unit, makes sure water source
is plumbed to chiller installation location. High points in
plumbing require vent valves; low points require drain
valves.
Chiller
Process machine
Alternate
locations
24 inches
(610 mm)
24 inches
(610 mm)
24 inches
(610 mm)
24 inches
(610 mm)
UGH016/0500 Series 1 Portable Chillers, TIC Control
INSTALLATION 3-5
M
AKING
PROCESS
PLUMBING
CONNECTIONS
Warm fluid from your process enters the chiller at the From
Process valve and chilled fluid returns to the process equipment through the To Process valve.
Remove the shipping plastic pipe plug from
the female connections on the back of the portable chiller.
Make sure the male pipe threads are clean
and new.
Wrap threads with Mylar or Teflon tape.
Connect the From Process valve and tubing
on the back of the chiller to the From Process tubing.
Start by hand until the threads engage and then tighten
with a pipe wrench. Tighten only enough to prevent leaks;
do not over-tighten!
Connect the To Process valve and tubing on
the back of the chiller to the return tubing. Start by hand
until the threads engage and then tighten with a pipe
wrench. Tighten only enough to prevent leaks; do not
over-tighten!
For the Water-cooled Chillers connect the water source for
cooling to the Condenser Water inlet on the back of the chiller.
Connect the Condenser Water outlet for returning water.
To Process valve
back view
From Process valve
1
2
3
4
5
Condenser
Water Outlet
(water-cooled only)
Condenser
Water Inlet
(water-cooled only)
Series 1 Portable Chillers, TIC Control UGH016/0500
3-6
INSTALLATION
F
ILLING THE
CHILLER
The Chiller is shipped without coolant. The chiller is filled
manually during installation. Use water as the coolant down to
40 °F (4 °C). Below 40 °F and down to 20 °F (-7 °C), use an
ethylene glycol or propylene glycol solution.
To fill with water:
Attach water hose to Fill/Drain valve.
Close the To Process and From Process valves.
Open the Fill/Drain valve and fill chiller
to the fill mark on the Water Level sight glass. If the
chiller is overfilled, the excess water spills out the vent
tube. DO NOT OVERFILL.
Close the Fill/Drain valve.
Disconnect water hose from Fill/Drain valve.
1
2
3
4
5
Fill/Drain valve
To Process valve
From Process valve
Water Level
sight glass
To fill with glycol solution:
Mix the glycol to the proper percentage.
Use the table to determine the percentage (by volume) of
glycol needed for the process temperature (in °F) you
require. Do not choose a temperature below 15 °F (-9 °C).
Mix the proper percentage of glycol with water.
1
WARNING: Refrigerant hazard
Only certified refrigerant technicians should
examine and correct problems involving the
refrigerant circuit.
UGH016/0500 Series 1 Portable Chillers, TIC Control
INSTALLATION 3-7
Temperature of Process Fluid °F
Glycol, % by Volume
Close the To Process and From Process valves.
Open the Fill/Drain valve and fill chiller
to the fill mark on the Water Level gauge. If the chiller is
overfilled, the excess fluid spills out the vent tube. DO
NOT OVERFILL.
Close the Fill/Drain valve.
Check the coolant level.
Once the chiller is turned on, the coolant level may drop
as the coolant begins to circulate, filling the connected
plumbing. Check the coolant level on the back of the
chiller. The water level shows on the water level gauge.
Make sure water level is filled to the mark on the gauge.
Change the minimum operating temperature
range to the correct setting for the percent glycol used.
See Setting the To Process Low Limit, in the Operations
section.
2
3
4
5
6
F
ILLING THE
CHILLER
CONT’D
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