Conair UGH031-0209 User Manual

EarthSmart

TM

ECM Series, 0.50 to 0.75 ton models

Corporate Office: 724-584-5500 l Instant Access 24/7 (Parts and Service): 800.458.1960 l Parts and Service: 814.437.6861

USER GUIDE

UGH031-0209

www.conairgroup.com

Please record your equipment’s
model and serial number(s) and
the date you received it in the
spaces provided.

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

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

Date:

Manual Number: UGH031-0209

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.

Copyright 2009 l The Conair Group l All rights reserved

Table of Contents

1-1 Introduction

Purpose of the user guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

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

Your responsibilities as a user . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

ATTENTION: Read this so no one gets hurt . . . . . . . . . . . . . . . . . . . 1-4

2-1 Description

What is the EarthSmart ECM Series Chiller?. . . . . . . . . . . . . . . . . . .2-2

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

Limitations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-3

How it works: Process circulation. . . . . . . . . . . . . . . . . . . . . . . . . . .2-4

Refrigeration circulation . . . . . . . . . . . . . . . . . . . . . . 2-5

Component listing . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6

Specifications: EarthSmart ECM Series Chiller. . . . . . . . . . . . . . . . . 2-8

Pump curve: EarthSmart ECM Series Chiller . . . . . . . . . . . . . . . . . . 2-9

3-1 Installation

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

Warning and cautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

Preparing for installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

Making process plumbing connections . . . . . . . . . . . . . . . . . . . . . . 3-5

Filling the chiller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6

Drain connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7

Checking the refrigerant charge . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8

Connecting the main power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9

4-1 Operation

EarthSmart ECM Series Chiller: Control descriptions . . . . . . . . . . . . 4-2

Starting the chiller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

Table of Contents l i

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

Changing temperature units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5

Chiller operation sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6

Resetting the high pressure switch of the compressor . . . . . . . . . . 4-8

5-1 Maintenance

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

Checking electrical connections . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4

Cleaning the brazed plate adapter . . . . . . . . . . . . . . . . . . . . . . . . . 5-5

Cleaning the air-cooled condenser . . . . . . . . . . . . . . . . . . . . . . . . . 5-7

Checking the reservoir level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9

Cleaning the pump strainer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10

Checking the refrigerant charge and quality . . . . . . . . . . . . . . . . . 5-12

6-1 Troubleshooting

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

A few words of caution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3

DIAGNOSTICS

How to identify the cause of a problem . . . . . . . . . . . . . . . . . . . . . 6-3

Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4

Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5

Checking or replacing the temperature sensor . . . . . . . . . . . . . . . . 6-8

Checking or resetting the circuit breakers . . . . . . . . . . . . . . . . . . . . 6-9

A Appendix

We’re here to help . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1

How to contact customer service . . . . . . . . . . . . . . . . . . . . . . . . . . A-1

Before you call... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1

Equipment guarantee . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-2

Performance warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-2

Warranty limitations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-2

ii l Table of Contents

B Appendix

Safety adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1

C Appendix

Water quality control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-1

D Appendix

Chiller capacity and derate chart . . . . . . . . . . . . . . . . . . . . . . . . . . D-1

E Appendix

Pressure-temperature chart for R-134A refrigerant . . . . . . . . . . . . . E-1

F Appendix

RTD resistance chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-1

G Appendix

Overhead plumbing details . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-1

H Appendix

Electrical schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H-1

I Appendix

Control Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-1

J Appendix

Plumbing schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J-1

Table of Contents l iii

iv l Table of Contents

Introduction

Purpose of the user guide. . . . . . . . . . . . . . 1-2

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

Your responsibilities as a user. . . . . . . . . . . 1-3

ATTENTION: Read this so no one gets hurt . . . 1-4

SECTION

1

Introduction l 1-1

1

Introduction

✐

Purpose of the User Guide

This User Guide describes the EarthSmart ECM Series Chiller 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.

How the Guide is Organized

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 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 circle marks items in a list.

Indicates a tip. A tip is used to provide you with a suggestion that will help you with
the maintenance and the operation of this equipment.

Indicates a note. A note is used to provide additional information about the steps
you are following throughout the manual.

1

◆

❒

•

✒

1-2 l Introduction

Introduction l 1-3

Your Responsibility as a User

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.

1

Introduction

ATTENTION:
Read this so no one gets hurt

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.

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

This equipment should be installed, adjusted and serviced by a quali­fied technician who is familiar with the construction, operation and
potential hazards of this type of machine.

All wiring, disconnects and fuses should be installed by a qualified
electrical technician 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: Voltage hazard

This equipment is powered by single-phase alternating current,
as specified on the machine serial tag and data plate.

A properly-sized conductive ground wire from the incoming power
supply must be provided. Improper grounding can result in severe
personal injury and erratic machine operation. (Units are supplied with
a grounded plug that must be plugged into a grounded out.)

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

1-4 l Introduction

(continued)

1

Introduction

Introduction l 1-5

CAUTION: Hot Surfaces

Always protect yourself from hot surfaces when working on the
chiller, especially when working on or around the compressor and
condenser. These devices can be over 160°F {71°C}. Allow these
devices to cool before performing any maintenance or
troubleshooting.

WARNING: Refrigerant hazard

Only certified refrigerant technicians should examine and correct
problems involving the refrigerant circuit.

ATTENTION:
Read this so no one gets hurt

(continued)

1-6 l Introduction

Description l 2-1

Description

What is the EarthSmart ECM Series Chiller?. . 2-2

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

Limitations. . . . . . . . . . . . . . . . . . . . . . . . 2-3

How it works: Process circulation . . . . . . . . 2-4

Refrigeration circulation . . . . . 2-5

Component listing . . . . . . . . . 2-6

Specifications: EarthSmart ECM

Series Chillers . . . . . . . . . . . . . . . . . . 2-8

Pump curve: EarthSmart ECM

Series Chillers . . . . . . . . . . . . . . . . . . 2-9

SECTION

2

2

Description

What is the EarthSmart ECM Series
Chiller?

The Conair EarthSmart ECM Series Chillers provide self-contained sources of
chilled water and are available with compressor ranges of 0.5 Hp or 0.75 Hp
(nominal capacities of 0.41 tons or 0.70 tons of refrigeration).

IMPORTANT: Nominal chilling capacities are based on 95°F {35°C} ambient air conditions and
processing 50°F {10°C} leaving water.

ECM Series Chillers are designed to provide chilled fluid 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.

Typical Applications

ECM Series Chillers can be used anywhere a reliable source of process cooling
water at temperatures ranging from 45° to 65°F {7.2°C to 18.3°C} is required.
These chillers at full load, will discharge approximately 7,500 or 12,500
BTU/hr of heat into the atmosphere (depending on model).

Chillers are available for:

● Injection molding ● Dryer intercoolers/aftercoolers

● Blow molding ● Heatset/web offset printing presses

● Thermoforming ● Degreasing

● Extrusion ● Laser

● Air compressors ● Anodizing

● Metal plating

2-2 l Description

NOTE: Chiller’s environment

and cooling temperatures

below the default cooling

ranges will affect cooling

capacities.

✐

Description l 2-3

2

Description

Limitations

Conair EarthSmart ECM Series Chillers are chosen based on the cooling load,
ambient temperature and cooling temperature.

● Cooling load - Choose a chiller that has 0 - 10% more cooling capacity than

the process load to be chilled.

● Ambient temperature - The chiller’s air-cooled condenser requires an

ambient air temperature between 40° to 95°F {4.4° to 35°C} for efficient
operation. Operation above 95°F {35°C} may result in elevated condensing
pressures and will eventually cause the chiller to shut down due to a high
pressure safety switch. Contact Conair Service for information for operating
within ambient air temperatures above 95°F {35°C} or below 40°F {4.4.°C}.

● Temperature - As standard, ECM Series Chillers can provide cooling

temperature ranges of 45°F to 65°F {7.2°C to 18.3°C}. For cooling
temperatures below 45°F {7.2°C}, contact Conair Service.

Use this information as a general guide. Consult your Conair representative for
assistance when choosing a Conair EarthSmart ECM Series Chiller.

2-4 l Description

How it Works: Process Circulation

Hot fluid from the process enters the chiller
through the “From Process” inlet into the
chiller’s reservoir.

Pump moves fluid from the reservoir through
evaporator where it is chilled.

Fluid is chilled in the evaporator and exits
through the “To Process” outlet, returning to
the process.

1

2

3

1

2

3

(Left-side as viewed from the control)

2

Description

Description l 2-5

How it Works: Refrigerant Circulation

The evaporator extracts heat from the process fluid,
causing the refrigerant to vaporize (evaporate) into a gas.

Vaporized refrigerant travels to the compressor, where the
low-pressure vapor is compressed into a high-pressure,
high-temperature vapor.

The high-pressure, high-temperature vapor travels from the
compressor through the condenser, where the fan cools
and condenses the vapor into a high-pressure, high­temperature liquid.

High-pressure, high-temperature liquid is metered back to
the evaporator by the expansion valve (TXV), changing it
to a low-pressure, low-temperature vapor.

1

3

3

To Process outlet

From Process inlet

Drain/Fill

Pump

(Left-side as viewed from the control)

(Right-side as viewed from the control)

1

2

4

2

4

How it Works: Component Listing

Water system

• Motor/Pump assembly - The motor/pump assembly circulates chilled

coolant through the process loop. The pump assembly is built with brass to
maintain water quality.

Refrigeration system

• Compressor - Hermetic compressor takes low-pressure, low-temperature

refrigerant gas and compresses the gas into high-pressure, high-temperature
vapor.

•

Air-cooled condenser - The air-cooled condenser removes heat BTUs from

the compressor refrigerant gas. The action causes the gas to “condense” into a
liquid state still under high pressure. Air flow across the condenser is
achieved by a motor driven fan.

•

Fan cycling switch - The fan cycling switch is adjustable when the chiller is

in an environment cooler than 95°F {35°C}. See Appendix J entitled,

Plumbing Schematic.

• Filter-dryer - The filter-drier removes contaminants and moisture from the

liquid refrigerant.

• Liquid receiver - Serves as a collection tank for high-pressure liquid

refrigerant to ensure total charge at all times.

• Refrigerant sight glass - The refrigerant sight glass indicates refrigerant

charge and moisture content. Refrigerant charge is determined by a clear
liquid flow. Bubbles indicate low refrigerant. Moisture content is indicated by
the color of the sight glass view port element. The element’s color is normally
green. If the color of the element is dark brown or yellow, the system has
been contaminated with moisture and the refrigerant circuit needs to be
serviced by a qualified refrigerant service technician. See Maintenance

section entitled, Checking the Refrigerant Charge and Quality.

• Expansion valve - The expansion valve meters flow of liquid refrigerant

into the evaporator and creates a pressure drop in the refrigerant system that
allows the liquid refrigerant to “boil off” inside the evaporator.

2-6 l Description

(continued)

• Evaporator - The evaporator is a brazed plate heat exchanger where the

liquid refrigerant is allowed to evaporate (boil off) to absorb the heat (BTU)
from the process fluid. As the heat is absorbed, the process fluid is chilled.

• High/Low Pressure Switches: The high/low pressure switches protect the

refrigeration system from unsafe operating levels. The high pressure switch
is factory set to open at 230 PSI and protects the refrigeration components
and personnel from potential damage or injury from excessively high
pressure. The high pressure safety must not be altered in the field for any
reason. The low pressure switch is factory set to open at 25 PSI and to close
at 35 PSI. The low pressure switch protects the chillers from possible damage
due to low operating pressure. The low pressure switch is field adjustable for
setpoints below 45°F {7.2°C}, contact a Conair representative for more
information.

How it Works: Component Listing

(continued)

Description l 2-7

2

Description

IMPORTANT: Altering the High Pressure Switch setting will void any chiller warranty.

NOTE: The fan cycling switch

is adjustable when the chiller

is in an environment cooler

than 95°F {35°C}.

See

Appendix J entitled, Plumbing

Schematic.

✐

2-8 l Description

Specifications: EarthSmartTMECM
Series Chillers

A

B

C

TPHS039-1208

MODEL ECM-0.5 ECM-0.75

Performance characteristics

Capacity* tons 0.41 0.70
Compressor Hp {kW}

✝

0.5 {0.37} 0.75 {0.56}
Pump Hp {kW} 0.25 {0.19} 0.5 {0.37}
Chilled water flow‡gpm {lpm} 0.9 {3.4} 1.7 {6.4}
Chilled water pressure‡psi {bar} 60 {4.1} 60 {4.1}
Reservoir capacity gal {liters} 10 {37.8} 10 {37.8}

Dimensions inches {mm}

A - Height 39.7 {1008} 39.7 {1008}
B - Width 18.7 {475} 18.7 {475}
C - Depth 24.2 {615} 24.2 {615}

Process connections inches {mm}

Process (to and from) 0.5 0.5

Weight lb {kg}

§

Installed 223 {101} 233 {106}
Shipping 170 {77} 180 {82}

Voltages full load amps

**

115V/1 phase/60Hz 14 NA
220V/1 phase/60Hz NA 11

Refrigerant

R-134A

Refrigerant charge lb {kg}

1.3 {0.6} 1.3 {0.6}

SPECIFICATION NOTES:

* Ton capacity at 12,000 BTU/ton @ 50°F {10°C} leaving

water temperature @ 115°F {46°C} condensing tempera­ture. Capacities may be ± 5% as reserved by the
compressor manufacturer. Capacity multipliers are: 50°F
{10°C} - 1.00; 40°F {4.4°C} - 0.80.

✝

The ECM Series Chiller uses a hermetic reciprocating
compressor.

‡

Consult pump curve for exact characteristics relating to
pump performances.

§

Chiller installed weight includes a completely filled

reservoir.

**

No allowance for inrush current. Ground fault interruption
to be supplied by the customer. Full load amps must be
used to size supply conductors. Consult a Conair repre­sentative for 50 Hz operation.

Specifications can change at any time. Contact your Conair
representative for the most current information.

Description l 2-9

2

Description

Pump Curve: EarthSmartTMECM
Series Chillers

25

50 75 100 125 150 175 200 225 25025

20

30

40

50

60

70

80

90

100

110

120

130

140

10

0.00

0.05

0.10

0.15

0.20

0.25

0.30

0.35

0.40

0.45

0.50

0.55

0.60

0.65

Outlet Pressure* (PSI)

Horsepower

Flow Rate (GPH at 1725 RPM)

SPECIFICATION NOTES

* Pump curves do not reflect pressure drops due to internal piping.

This pump curve is non-overloading using the service factor of the motors.

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

100 GPH

100 GPH

Horsepower Flow rate

2-10 l Description

Installation l 3-1

Installation

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

Drain connection . . . . . . . . . . . . . . . . . . . . 3-7

Checking the refrigerant charge . . . . . . . . . 3-8

Connecting the main power . . . . . . . . . . . . . 3-9

SECTION

3

3

Installation

3-2 l Installation

Unpacking the Boxes

The EarthSmart ECM Series Chiller comes fully assembled in a single crate.
Units are shipped with the casters attached.

1 Carefully uncrate the chiller and its components.

2 Remove all packing material, protective paper, tape and plastic. Compare

contents to the shipping papers to ensure that you have all the parts.

3 Carefully inspect all components to ensure no damage occurred during ship-

ping. If any damage is found, notify the shipping agent immediately to file a
claim. 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.

4 Cut the bands holding the chiller onto the pallet.

5 Record serial numbers and specifications for the chiller in the blanks

provided on the back of this User Guide’s title page. This information will be
helpful if you ever need service or parts.

CAUTION: Lifting

Conair EarthSmart ECM Series 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 been positioned at the chiller’s center of gravity. Do not try to lift the
chiller manually.

Installation l 3-3

3

Installation

Warnings and Cautions

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

This equipment should only be installed, adjusted and serviced by a qualified
technician who is familiar with the construction, operation and potential
hazards of this type of machine.

All wiring, disconnects and fuses should be installed by a qualified electrical
technician in accordance with electrical codes in your region. Always maintain
a safe ground. Do not operate this equipment at power levels other than what
is specified on the machine data plate.

CAUTION: Hot Surfaces

Always protect yourself from hot surfaces when working on the chiller,
especially when working on or around the compressor and condenser. These
devices can over 160°F {71°C}. Allow these devices to cool before performing
any maintenance or troubleshooting.

CAUTION: Ventilation

The unit requires a clean and well ventilated operating environment. Do not
place anything on top of the unit while operating.

Units require enough clearance around the perimeter for access panels to be
removed completely. Units require a minimum of 2 ft {0.6 m} clearance around
the perimeter for proper air flow.

WARNING: Refrigerant hazard

Only certified refrigerant technicians should examine and correct problems
involving the refrigerant circuit.

Preparing for Installation

Plan the location for the chiller and prepare the area properly.

Position the chiller as close to the process machine as possible. Place the chiller in
position near the process machine so that coolant 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 a qualified technician and
comply with your region’s electrical codes.

❒❒

Clearance for safe operation and maintenance.

Ensure there is 2 ft {0.6 m} of clearance at the air intake and 2 ft
{0.6 m} of clearance at the exhaust discharge for proper operation. Air
flow is generated by the motor driven fan. Air flow is from the outside
of the chiller, through the condenser and exhausted through the unit.
Exhaust air can not be ducted on motor driven fan models.

Position the locking casters to prevent the chiller from moving. For
maintenance and servicing, be sure there is enough clearance to
remove all access panels completely.

❒❒

Available water source.

Ensure water make-up source is plumbed to the chiller’s installation
location. High points in the plumbing require vent valves; low points
require drain valves.

3-4 l Installation

NOTE: Models must be posi-

tioned so that the condenser

air inlet is no warmer than

95°F {35°C} and the condenser

air outlet is not blocked or

restricted in any way.

✐

Chiller

Process machine

Alternate
locations

NOTE: Locate models away

from heat producing equip-

ment. These items will affect

ambient air conditions and the

performance of the chiller.

✐

Installation l 3-5

3

Installation

Making Process Plumbing
Connections

All process piping materials (such as hoses, rigid piping, valves or filters) used
with process water piping circuitry must be rated for 100°F {37.8°C} minimum
temperature and 150 PSI {10.3 bar} minimum pressure.

All such materials must have the equivalent or larger diameter of the particular
process connection that the length of process water piping is connected to.

Process water piping circuitry should be designed to avoid an excessive use of
elbows and/or lengths of pipe or hose. If hose is the material of choice, avoid
tight twists or curls and excessive lengths.

Valves and filters may be installed in the process water piping circuitry to
facilitate service and maintenance provided that these devices maintain the full
inside diameter of the process connection. If installed, all devices must be open
and clean during unit operation.

Warm coolant from process equipment enters the chiller at the “From Process”
inlet and chilled coolant returns to the process equipment through the “To
Process” outlet.

To connect process plumbing:

1 Remove the shipping plastic pipe plugs from the female “To Process” and

“From Process” connections on the back of the portable chiller.

2 Make sure the male pipe threads are clean and new.

3 Wrap the male pipe threads with Teflon tape or pipe dope.

4 Connect the “From Process” valve (factory optional) on the back of the

chiller to the “From Process” tubing that is from the “Water Out” mani­fold on the mold or process. Start by hand until the threads engage and then

tighten with an appropriately-sized pipe wrench. Tighten only enough to pre­vent leaks; do not over-tighten.

5 Connect the “To Process” valve (factory optional) on the back of the chiller

to “To Process” tubing that is from the “Water In” manifold on the mold
or process. Start by hand until the threads engage and then tighten with an

appropriately-sized pipe wrench. Tighten only enough to prevent leaks; do not
over-tighten. If process lines are higher than the chiller, see Appendix G, entitled

Overhead Plumbing Details.

From Process
inlet

To Process
outlet

Fill/drain port

NOTE: The ability of the unit to

maintain process temperature

control depends on the method

of installation.

✐

NOTE: Assure the piping

installation has continuous

flow at all times. If using a

mechanical valve to regulate

process flow you MUST install

a bypass in the process

piping.”

✐

3-6 l Installation

Filling the Chiller

The chiller is shipped without coolant. The chiller is manually filled during instal­lation using water as its coolant.

For atypical process temperatures below 45°F {7.2°C}, use the table below to
determine the percentage (by volume) of glycol needed for the process tempera­ture that is required. Mix the proper percentage of glycol with water.

To fill with water:

1 Attach the water supply to the Fill/Drain valve, located on the back of the

chiller.

2 Open the “To Process” and “From Process” valves (factory optional).

3 Open the Fill/Drain valve or water supply and fill the chiller to the 7/8 full

level on the water level gauge. If the chiller is overfilled, the excess water
spills out the vent tube. DO NOT OVERFILL.

4 Close the Fill/Drain valve.

5 Check the coolant level. When the chiller is turned on the coolant level drops

as it begins to circulate, filling the connected plumbing. Check the
coolant level on the back of the chiller. Make sure the coolant level is filled to
the 7/8 full level on the water level gauge. Shut down the chiller and add more
coolant, if needed.

6 Disconnect water hose from Fill/Drain valve, if the chiller is to be used

elsewhere.

Recommended Percentages of Glycol for

Chilled Water Freeze Protection (by volume)

Discharge water % Propylene % Water

Temperature Glycol

40°F 20 80

30°F 30 70

25°F 40 60

IMPORTANT: The chiller’s control does not monitor the percentage mixture of glycol.

IMPORTANT: Evaporator freeze-ups

are not

covered under warranty.

Installation l 3-7

3

Installation

Drain Connection

To drain the chiller for storage or transport:

1 Rotate the chiller’s drain valve counterclockwise. If using chemicals or

additives with your process coolant, observe local disposal laws and regulations.

2 Close the chiller’s drain valve by turning it clockwise once final

evacuation of all process coolant is complete.

IMPORTANT: Drainage procedures must be done prior to shipment or outdoor storage of
the unit. If not, freezing damage can occur.

From Process inlet

To Process outlet

Fill/drain port

Water level gauge

IMPORTANT: Ensure long-term storage environments are above freezing temperatures. If
not, allow the chiller to thaw for several hours before returning it to operation or fill the
chiller’s internal piping with a high mixture of glycol to water during storage.

3-8 l Installation

Checking the Refrigerant Charge

WARNING: Refrigerant hazard

Only certified refrigerant technicians should examine and correct problems
involving the refrigerant circuit.

All chillers are fully charged with R-134A refrigerant from Conair. Your chiller’s
model nameplate identifies the type and amount of total refrigerant charge
required.

Check the refrigerant charge while the chiller is running through the sight glass.
Locate the sight glass by removing the left-side panel and using a flashlight, if
necessary to check the sight glass:

❒❒

Under full load conditions, the refrigerant should be clear (no bubbles).

❒❒

Under low load conditions, when the Hot-gas Bypass valve is energized,

bubbles may be visible in the sight glass. This is normal.

If the charge is low and the unit is under warranty, contact Conair service.
Otherwise have a local, certified refrigeration technician add R-134A refrigerant to
the system.

Sight glass

NOTE: In this diagram, the

chiller’s panels are removed

for clarity.

✐

CAUTION: Always disconnect and lock out the main power sources before making
electrical connections. Electrical connections should be made only by a qualified
electrical technician.

Connecting the Main Power

The Conair EarthSmart ECM Chiller uses standard 115 Volt, 60 Hz or 220 Volt,
60Hz single-phase power, depending on model.

To connect the the main power to the chiller:

1 Connect the chiller’s plug into a properly-sized and rated electrical outlet.

IMPORTANT: Always refer
to the wiring diagrams that
came with your chiller to
locate specific electrical
components. Illustrations in
the User Guide are intended
to be representative only.

CAUTION: Always disconnect and lock out the main power sources before making
electrical connections. Electrical connections should be made only by a qualified
electrical technician.

Installation l 3-9

3

Installation

220 Volt/60 Hz,
20 amp plug

IMPORTANT: Depending on the state of the refrigeration system the compressor may turn on

momentarily upon connecting power. The compressor will stop when the refrigerant is

pumped into the condenser and a low pressure condition exists in the evaporator.

3-10 l Installation

SECTION

4

4

Operation

Operation

EarthSmart ECM Series Chiller:

Control descriptions . . . . . . . . . . . . . . . 4-2

Starting the chiller . . . . . . . . . . . . . . . . . . 4-3

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

Changing temperature units . . . . . . . . . . . . 4-5

Chiller operation sequence . . . . . . . . . . . . . 4-6

Resetting the high pressure switch

of the compressor . . . . . . . . . . . . . . . . 4-8

Operation l 4-1

12 %

SD

EarthSmart ECM Chiller: Control Descriptions

Hot-Gas
Bypass Status

Indicates the status
of the Hot-Gas
Bypass valve.

Actual Chiller
Temperature

Shows the (process) actual
temperature value.

On/Off Toggle
Switch

Used to turn the
power to the chiller
on or off.

Alarm Indication

Indicates the alarm sta­tus. (High Temperature
Alarm only.)

Setpoint
Temperature

Shows the user­entered setpoint
temperature value.

4-2 l Operation

Control Codes

See See Trouble-

shooting section for

a list of possible
causes and solutions
for alarm condi­tions.

Infinity Button

Pressing the
“Infinity” button
will acknowledge
alarms and return
the user to the Main
screen.

Return Button

Pressing the “Return” button will
scroll through the chiller’s menu
screens.

Increment/
Decrement
Buttons

Used to increase or
decrease the user­entered process
temperature set­point.

4

Operation

Operation l 4-3

Starting the Chiller

To start the chiller:

1 Toggle the power switch to the On or “I” position. The control display will

illuminate. Facing the chiller’s control, the “To Process” actual temperature
will be on the left, the setpoint temperature is on the right. See Operation

section entitled, Chiller Sequence of Operation.

2 Set the cooling temperature setpoint. Use the up arrow button ▲ on the

control, to raise the setpoint. Use the down arrow button ▼ to lower the set­point. The temperature will ramp up at approximately 1 (one) degree per
second. After 2 (two) seconds of inactivity the setpoint entered will become
the targeted setpoint temperature.

On Position

NOTE: If the setpoint displays “OFF”
in the display, raise the setpoint
with the up arrow button

▲ to see

the actual setpoint.

✐

12 %

SD

Infinity Button

Pressing the “Infinity” button will acknowledge alarms
and return the user to the Main screen.

4-4 l Operation

Stopping the Chiller

To stop the chiller:

1 Toggle the power switch to the Off or “O” position.

Off Position

12 %

SD

IMPORTANT: Do NOT rapidly cycle the chiller’s power on and off (short cycle). Once the
power has been turned off, wait at least three (3) minutes before cycling the chiller’s
power back on.

4

Operation

Operation l 4-5

Changing Temperature Unit

To stop the chiller:

1 Press the green “Return” button once to access the Temperature Units

Selection screen. Press the ▲ or ▼ buttons to toggle between fahrenheit and
celsius temperature units.

2 Press the “Infinity” button to lock in the selection and return to the

Main screen. The control will default back to the Main screen if no buttons are
pressed after 1 minute.

12 %

SD

Return
Button

12 %

SD

Infinity
Button

NOTE: The temperature display will
not indicate Fahrenheit or Celsius
temperature units. The chiller’s
control is set for Fahrenheit tem­perature units as standard from
Conair.

✐

4-6 l Operation

Chiller Operation Sequence

The EarthSmart ECM Series Chiller has a unique user interface that controls the
process temperature and prevents refrigeration migration during compressor off
times.

When the main power is connected:

1 Depending on the state of the refrigeration system, the compressor may

turn on momentarily upon connecting power. The compressor will stop when
the refrigerant is pumped into the condenser and a low pressure condition exists
in the evaporator.

When the power toggle switch is turned to the “On”or “I” position:

2 Turning the toggle switch on immediately starts the process pump and

illuminates the control. When flow is established and the unit is not in a low
temperature alarm, the Liquid Line Solenoid valve (LLSV) will open. This
allows the refrigerant to migrate to the evaporator and increase the pressure.
When the low refrigerant pressure switch is satisfied the compressor will turn on
and process coolant will begin cooling.

3 When the process temperature is above setpoint the compressor will run

and the Hot-Gas Bypass valve (HGBP) will not open. If the process
temperature falls below the setpoint, the HGBP valve will energize, raising the
actual process temperature to maintain the user-entered setpoint temperature.
The HGBP valve can energize up to 9 out of 10 seconds. If there is less load
on the chiller and the temperature continues to fall to 4°F {2.2°C} below the
user-entered setpoint the controller will alarm (A2.lo) and close the LLSV. The
compressor will pump the refrigerant out of the evaporator and the low pressure
switch will shut off the compressor. This is a normal function of the chiller and
will not require troubleshooting.

4 The controller stays in this alarm condition (A2.lo) until the temperature is

2°F {1.1°C} above the user-entered setpoint, at which point the controller
allows the LLSV to re-open and the compressor to restart.

(continued)

Operation l 4-7

4

Operation

Chiller Operation Sequence (continued)

5 The condenser fan can energize anytime the toggle switch is in the “On”

or “I” position. The fan is controlled by the fan cycling (high refrigeration)
pressure switch. This switch maintains the high side refrigeration pressure
under cooler ambient temperatures and lower loads. The fan will turn on when
the high refrigeration pressure reaches 200 PSI {13.8 bar}. It will turn off
when the pressure drops below 125 PSI {8.6 bar}.

6 The high refrigeration safety pressure switch shuts off the compressor

immediately when the high refrigeration pressure reaches 230 PSI
{15.9 bar} without going through pump down during a low pressure cycle.

If the high pressure switch trips, it must be manually reset by pressing the
“Reset” button on the switch. The compressor can start immediately when
this is reset so caution should be exercised. See Operation section entitled,

Resetting the Compressor’s High Pressure Switch.

CAUTION: The compressor can start immediately when the High Pressure “Reset”
button is pressed.

4-8 l Operation

Resetting the High Pressure Switch
of the Compressor

The high refrigeration safety pressure switch shuts off the compressor
immediately when the high refrigeration pressure reaches 230 PSI {15.9 bar}
without going through pump down during a low pressure cycle. If the high
pressure switch trips, it must be manually reset by pressing the “Reset” button
on the switch. The compressor can start immediately when this is reset so
caution should be exercised.

To reset the high refrigeration safety switch:

1 Be sure the main power is disconnected and the chiller is locked out. Always

disconnect/unplug and/or lockout the main power source before opening the unit
for servicing.

2 Remove the chiller’s right-side panel, as viewed from the control.

3 Locate the high refrigeration safety switch within the top portion of the

chiller’s cabinet.

4 Push the “Reset” button, until there is a “click”.

5 Replace the chiller’s right-side panel, as viewed from the control.

6 Reapply main power.

Reset
Button

NOTE: The High Pressure
Safety switch may not reset
due to the chiller’s refrigerant
state. Allow the refrigerant to
cool before attempting to
reset.

✐

CAUTION: The compressor can
start immediately when the
High Pressure “Reset” button
is pressed.

Maintenance

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

Checking electrical connections. . . . . . . . . . 5-4

Cleaning the brazed plate adapter . . . . . . . . 5-5

Cleaning the air-cooled condenser . . . . . . . . 5-7

Checking the reservoir level . . . . . . . . . . . . 5-9

Cleaning the pump strainer . . . . . . . . . . . . 5-10

Checking the refrigerant charge

and quality . . . . . . . . . . . . . . . . . . . . 5-12

SECTION

5

Maintenance

5

Maintenance l 5-1

5-2 l Maintenance

Preventative Maintenance Schedule

Daily, or as often as needed

❒

Checking process fluid level in the pump tank

Check the process fluid level in the water level gauge on the back of the
chiller. If low, see Maintenance section entitled, Checking the Reservoir

Level.

❒

Verifying pump discharge pressure

While the pump is running, check to ensure that the pump pressure gauge
(located on the front of the chiller) is within range. To change the pressure,
open or close the “To Process” valve (factory optional).

❒

Inspecting piping for leaks

Check to see that pipes are not leaking. Look for standing water on the floor
or inside the chiller cabinet.

❒

Inspecting the condenser coil for debris

Check the condenser for adequate air flow. Check the condenser face for
dirt and clogging. If dirt or clogs are present, clean the condenser, see

Maintenance section entitled, Cleaning the Air-cooled Condenser. Check,

clean, and/or replace the filter at the air inlet of the air-cooled condenser coil,
as needed.

Weekly, or as often as needed

❒

Checking temperature and pressure readings

Check that the temperature displays on the control screen and the reading on
the pressure gauge (located on the front of the chiller) indicates normal
operation. See Description section entitled, Pump Curve: EarthSmart ECM

Series Chillers.

❒

Inspecting the filter

Check, clean and/or replace the filter at the air inlet of the air-cooled con­denser coil, as needed. see Maintenance section entitled, Cleaning the Air-

cooled Condenser.

❒

Checking refrigerant site glass

There should not be any bubbles. See Maintenance section entitled,

Checking the Refrigerant Charge and Quality.

❒

Checking reservoir level

Check the water level gauge on the back of the chiller. If fluid level is low,
fill, see Maintenance section entitled, Checking Reservoir Level.

(continued)

Maintenance l 5-3

Preventative Maintenance Schedule

(continued)

Monthly

❒

Inspecting cooling water treatment system

If your chiller uses a cooling water treatment system, maintain proper chemi­cal levels and follow the recommendations of your water treatment specialist.
Change water in the reservoir tank monthly to reduce water hardness.

❒

Checking electrical connections, amps and volts

Check to ensure the electrical connections are properly seated and that the
chiller is operating at its rated amps and voltage. See Description section

entitled, Specifications: EarthSmart ECM Series Chillers.

❒

Cleaning

Wipe all external surfaces to maintain performance.

❒

Inspecting condenser

Check the air-cooled condenser for adequate air flow. Check the condenser
face for dirt and clogging. If dirt or clogs are present, clean the condenser.
Check, clean and/or replace the filter at the air inlet of the air-cooled con­denser coil, as needed. See Maintenance section entitled, Cleaning the Air-

cooled Condenser.

❒

Inspecting the control panel

Check for loose wires, burned contacts and signs of overheated wires.
Check that all panel lights illuminate. See Maintenance section entitled,

Checking Electrical Connections.

❒

Checking refrigerant charge and quality

With the compressor running, check the sight glass between the receiver and
evaporator for proper refrigerant condition. See Maintenance section entitled,

Checking Refrigerant Charge and Quality.

❒

Checking the pump strainer.

Check to ensure the pump strainer is not clogged or damaged, replace as
needed. See Maintenance section entitled, Cleaning the Pump Strainer.

Annually

❒

Cleaning the evaporator

See Maintenance section entitled, Cleaning the Brazed Plate Evaporator.

❒

Check refrigerant piping

Verify that no oil is present on fittings or cabinet. Wipe clean and check
charge/operation of circuit.

5

Maintenance

5-4 l Maintenance

Checking Electrical Connections

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. Be sure that
power to the chiller is OFF when doing any maintenance on the chiller. Follow all
safety rules when performing any maintenance on this equipment.

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

This equipment should only be installed, adjusted and serviced by a qualified
technician who is familiar with the construction, operation and potential hazards
of this type of machine.

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

To check electrical connections:

1 Be sure the main power is disconnected and/or the chiller is locked out. Always

disconnect/unplug and lockout the main power source before opening the unit for
servicing.

2 Remove the chiller’s top lid, by first removing both side panels and then the four

(4) retaining bolts that secure the chiller’s top lid.

3 Inspect all wires and connections.

Look for loose wires, burned contacts and signs of over-heated wires. Compare
the wiring to the wiring diagrams you received with your chiller. Have a qualified
electrician make any necessary repairs or replacements.

4 Replace the chiller’s side panels and then the top lid by replacing the four (4)

retaining bolts.

5 Inspect the exterior power cords.

Cords should not be crimped, exposed or rubbing against the frame. If the main
power cord runs along the floor, make sure it is positioned where it could not rest
in pooling water or could not be ran over and cut by wheels or casters.

NOTE: Always refer
to the wiring dia­grams you received
with your chiller to
locate specific elec­trical components.

✐

NOTE: Also inspect
the chiller’s plug
wiring terminations.

✐

Cleaning the Brazed Plate Evaporator

Minerals and other contaminants produce deposits, scales, slime or algae on the heat
transfer surfaces exposed to water. Fouled surfaces could result in decreased cooling
capacity. Implement a water treatment program to slow the fouling.

CAUTION: Hot Surfaces

Always protect yourself from hot surfaces when working on the chiller, espe­cially when working on or around the compressor and condenser. These
devices can reach over 160°F {71°C}. Allow these devices to cool before
performing any maintenance or troubleshooting.

Water quality should be maintained at a pH level of 7.4, but not less than 6.0 for
proper heat exchanger life.

To clean the brazed plate adapter:

1 Prepare a 5% solution of Phosphoric acid or Oxalic acid and water. Do not

heat the acid solution.

2 Disconnect and/or lockout main power to the chiller.

3 Shut the “To” and “From Process” valves (factory optional) and the drain

reservoir. See Installation section entitled, Drain Connection.

4 Remove the chiller’s side panels.

5 Disconnect the pump from the heat exchanger. Install a cap in the opening of

the heat exchanger where the pump was connected.

Maintenance l 5-5

NOTE: These connections
may vary depending on the
model you have purchased.
Be sure to see the labeling on
your particular unit.

✐

5

Maintenance

From Process inlet

To Process outlet

Fill/drain port

Water level gauge

(continued)

5-6 l Maintenance

Cleaning the Brazed Plate Evaporator

(continued)

5 Remove RTD from bottom of evaporator.

6 Connect 3/8-inch tubing to the 3/8-inch connections of the heat exchanger.

SEE below to install customer-supplied chemical pump and solution fitted to the
heat exchanger.

7 Back-flush the solution through the heat exchanger and the chiller.

8 Flush the heat exchanger and the chiller piping with fresh water after

cleaning.

9 Reconnect the chiller pump to the heat exchanger. Remove the cap in the heat

exchanger and reconnect the hose to the pump.

NOTE: These connections
may vary depending on the
model you have purchased.
Be sure to see the labeling on
your particular unit.

✐

Acid
solution

Fluid circuit

Heat
Exchanger

To pump

To Process
connection

Valve

Pump

CAUTION: Hot Surfaces

Always protect yourself from hot surfaces when working on the chiller,
especially when working on or around the compressor and condenser. These
devices can reach over 160°F {71°C}. Allow these devices to cool before
performing any maintenance or troubleshooting.

5

Maintenance

Cleaning the Air-Cooled Condenser

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. Be
sure that power to the chiller is OFF when doing any maintenance on the
chiller. Follow all safety rules when performing any maintenance on this
equipment.

CAUTION: Hot Surfaces

Always protect yourself from hot surfaces when working on the chiller,
especially when working on or around the compressor and condenser. These
devices can reach over 160°F {71°C}. Allow these devices to cool before
performing any maintenance or troubleshooting.

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

To clean the air-cooled condenser:

1 Disconnect and/or lockout main power to the chiller.

2 Remove the chiller’s top lid, by first removing both side panels and then the four

(4) retaining bolts that secure the chiller’s top lid.

3 Remove the filter, that is located towards the back of the chiller, by lifting it

straight up and out of the chiller.

4 Inspect the condenser coils. Use a flashlight to check between coil surfaces.

5 Clean the dirty coils with a soft brush.

6 Flush with cool water or a commercial coil cleaner that is compatible with

aluminum alloys. It is recommended that the coil cleaner is sprayed from inside
the cabinet.

Maintenance l 5-7

(continued)

Cleaning the Air-Cooled Condenser

(continued)

7 Check the air filter. If the filter is blinded or torn, replace the filter.

8 Replace the chiller’s side panels and then the top lid by replacing the four (4)

retaining bolts.

9 Reapply main power.

CAUTION: Wear eye protection.

If you use compressed air to clean the equipment, you must wear eye pro­tection and observe all OSHA and other safety regulations pertaining to the
use of compressed air.

Replacement air filters are
available from Conair.

Contact Conair Parts
[phone]
From outside of the
United States, call:
[phone]

5-8 l Maintenance

Maintenance l 5-9

Checking Reservoir Level

WARNING: Electrical Hazard

Before performing any work on the chiller, disconnect and lock out electrical
power sources to prevent injury from unexpected energization or startup. Be
sure that power to the chiller is OFF when doing any maintenance on the
chiller. Follow all safety rules when performing any maintenance on this
equipment.

Check the coolant level in the reservoir. The coolant level in the sight glass on the
back of the chiller should be 7/8 full.

To manually fill the reservoir:

1 Disconnect and lockout power to the chiller.

2 Locate the Fill/Drain valve on the back of the chiller. Open the Fill/Drain valve

or coolant supply and fill the chiller to the 7/8 full level on the water level gauge.
If the chiller is overfilled, the excess water spills out the vent tube. DO NOT
OVERFILL.

3 Refill the reservoir. Monitor the level using the water level indicator on the back

of the chiller, ensuring you are adding the correct fluid for your application.

4 Close the Fill/Drain valve.

5 Check the coolant level. When the chiller is turned on the coolant level drops

as it begins to circulate, filling the connected plumbing. Check the
coolant level on the back of the chiller. Make sure the coolant level is filled to
the 7/8 full level on the water level gauge. Shut down the chiller and add more
coolant, if needed.

6 Disconnect water hose from Fill/Drain valve, if the chiller is to be used

elsewhere.

Fill/drain port

Water level gauge

5

Maintenance

Cleaning the Pump Strainer

EarthSmart Chillers use a rotary pump to flow process coolant through their internal
piping and to the process. A strainer on the pump may periodically need cleaning,
depending upon the quality of the process coolant.

WARNING: Electrical Hazard

Before performing any work on the chiller, disconnect and lock out electrical
power sources to prevent injury from unexpected energization or startup. Be
sure that power to the chiller is OFF when doing any maintenance on the
chiller. Follow all safety rules when performing any maintenance on this
equipment.

To clean the pump’s strainer:

1 Be sure the main power is disconnected and/or the chiller is locked out. Always

disconnect/unplug and lockout the main power source before opening the unit for
servicing.

2 Drain all process coolant from the chiller, see Installation section entitled, Drain

Connection.

3 Remove the chiller’s right-side panel. (As viewed from the control)

4 Locate the chiller’s pump. It is located in the lower portion of the chiller’ cabinet

and towards the front of the chiller.

5 Locate the pump strainer’s end cap, remove the cap by unscrewing it counter-

clockwise with an appropriately-sized wrench.

5-10 l Maintenance

Strainer end cap

NOTE: The front panel of the
chiller has been removed in
this image for clarity.

✐

(continued)

Cleaning the Pump Strainer (continued)

6 Remove the strainer from its housing.

7 Inspect the strainer for holes or blinding, clean or replace as necessary.

8 Re-install the strainer and strainer cap. Properly seal all piping with approved

Teflon tape or pipe dope.

9 Check to ensure no leaking has occurred before returning the chiller to normal

operation.

Replacement strainers are
available from Conair.

Contact Conair Parts
[phone]
From outside of the
United States, call:
[phone]

IMPORTANT: Check to ensure the strainer is properly seated before applying the strainer
cap. Crushing of the strainer can occur if it is not fully inserted back into the strainer
housing.

5

Maintenance

Maintenance l 5-11

5-12 l Maintenance

Checking the Refrigerant Charge and
Quality

WARNING: Refrigerant Hazard

Only certified refrigerant technicians should examine and correct problems
involving the refrigerant circuit.

All chillers are fully charged with R-134A refrigerant from Conair. Your chiller’s
model nameplate identifies the type and amount of total refrigerant charge required.

See Description section entitled, Specifications: EarthSmart ECM Series Chillers.

Check refrigerant charge while the chiller is running under normal load. Check the
refrigerant charge through the sight glass. Use a flashlight, if necessary, and check the
liquid-line sight glass:

• Under full load conditions, the refrigerant should be clear (no bubbles).

• Under low load conditions, when the Hot-Gas Bypass valve (HGBP) is

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

A refrigerant quality label is located within the sight glass. A green label is normal. A
yellow or dark brown label indicates that the refrigerant is contaminated and must be
replaced.

If the charge is low or contaminated and the chiller is under warranty, contact Conair
service; or have a local, certified refrigeration technician service the system.

Sight glass

CAUTION: Always disconnect and lock out the main power sources before making
electrical connections. Electrical connections should be made only by a qualified
electrical technician.

NOTE: In this diagram, the

chiller’s panels are removed

for clarity.

✐

Troubleshooting

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

A few words of caution . . . . . . . . . . . . . . 6-3

DIAGNOSTICS

How to identify the cause of a problem . . . . 6-3

Alarms . . . . . . . . . . . . . . . . . . . . . . . . . 6-4

Troubleshooting . . . . . . . . . . . . . . . . . . . . 6-5

Checking or replacing the

temperature sensor . . . . . . . . . . . . . . . 6-8

Checking or resetting the circuit breakers. . . 6-9

SECTION

6

6

Troubleshooting

Maintenance l 6-1

Before Beginning

You can avoid most problems by following the recommended installation and
maintenance procedures outlined in this User Guide. If you do have a problem,
this section will help you determine what caused it and how to fix it.

❏ Diagnose causes from the control panel.

1 Note the alarm and press the “Infinity” button once to acknowledge

the alarm and resume control if required.

2 Address the alarm message and fix the problem. See Troubleshooting

section for descriptions of possible alarm conditions.

3 If the alarm reappears the problem was not fixed.

❏ Find the wiring and equipment diagrams that were shipped with your

chiller. These diagrams are the best reference for correcting a problem. The

diagrams also will note any custom features, such as special wiring or alarm
capabilities, not covered in this User Guide.

12 %

SD

This red light
indicates a
High
Temperature
alarm condition

The “Infinity”
button should be
pressed once to
acknowledge a
High Temperature
alarm.

6-2 l Troubleshooting

6

Troubleshooting

A Few Words of Caution

Improper corrective actions can lead to hazardous conditions and should
never be attempted to sustain production.

WARNING: Only a qualified electrical technician should examine and
correct problems that require opening the chiller’s electrical enclosure
or using electrical wires to diagnose the cause.

WARNING: High voltage. Always stop the chiller, disconnect and lock out
the main power source before troubleshooting or performing repairs.

CAUTION: Hot surfaces. Always protect yourself from hot surfaces inside
and outside of the chiller.

How to Identify the Cause of a
Problem

The High Temperature Alarm is indicated by an illuminated alarm light on
the EarthSmart ECM control panel and an alarm code, (A2.hi) is displayed in
the control display.

When an alarm code is displayed in the control:

1 Find the error message in the diagnostics table of this

Troubleshooting section and reference the control labeling in the upper
right-hand side of the control face.

2 Note that, after correcting the problem, pressing the “Infinity”

button will clear the alarm. The alarm will only clear if the
condition causing the alarm has been corrected.

Troubleshooting l 6-3

6-4 l Troubleshooting

Alarms

If the red alarm LED is illuminated, an alarm is activated. The chiller has automat­ically pumped down because it has detected a serious problem that could damage
your process or chiller. Note that the alarm must be acknowledged before the con­trol will resume operation by pressing the “Infinity” button.

Problem

A2.hi (Alarm light illuminat­ed) – If the “To Process”

temperature exceeds the
process high temperature devi­ation setpoint, it shuts down
the chiller. Default is set to
20°F {11.1°C}.

Er.in (Input error)

A2.lo – (Alarm light illumi-
nated) – If the “To Process”

temperature exceeds the
process low temperature devi­ation setpoint, it closes the liq­uid line solenoid valve and the
compressor pumps down and
shuts down. Default is set to
4°F {2.2°C}.

Possible cause

The Hot-gas Bypass valve is not
operating properly (stuck open).

Load is too high for the chiller.

Process coolant is not flowing between
the supply outlet and return inlet.

Dirty condenser coil.

Ambient temperature is above 95°F
{35°C}.

Warm process coolant.

Failed RTD.

Loose RTD connection to the control.

Reversed RTD input.

Load is too low for the chiller.

Solution

Have a certified refrigeration technician
replace the solenoid valve.

Remove some load from the process.

Check for plugged pipes, closed valves,
or failed flow switch(es).

Clean condenser coil. See Maintenance

section entitled, Cleaning the Air­cooled Condenser.

Lower ambient temperature or move
the chiller to a lower temperature envi­ronment.

Lower the temperature of the process
coolant.

Replace the RTD. See Troubleshooting

section entitled, Checking or Replacing
the Temperature Sensor and Appendix F
entitled, RTD Resistance Chart.

Check RTD connection to the controller.
Resecure as necessary.

Check RTD wiring.

The chiller’s compressor will automati­cally restart once the “To Process”
temperature exceeds the user-entered
setpoint on the control by 2°F {1.1°C}.

Troubleshooting l 6-5

6

Troubleshooting

Troubleshooting

Problem

The chiller will not start.
(Control not illuminated)

Pump will not start.

Possible cause

Tripped circuit breaker.

Incorrect incoming voltage.

The power toggle switch is not turned
to the “On” or “I” position.

Open motor winding.

Internal overload has tripped.

Loose wire connection or defective
start capacitor.

CB2 circuit breaker has been tripped.

Solution

Verify resistance to ground. Reset
breaker. See Troubleshooting section

entitled, Checking or Resetting the
Circuit Breakers.

Check incoming power source for
correct voltage and amperage as
detailed on the chiller nameplate. See

Description section entitled,
Specifications: EarthSmart ECM Series
Chillers.

Turn the power toggle switch on the
control to the “On” or “I” position.

Contact Conair Service.

Auto-resetting. Allow the chiller’s
motor to cool and restart the chiller.

Check wiring diagrams, see Appendix

H entitled, Electrical Schematic,

replace connections or capacitor.

Verify resistance to ground. Reset
breaker. See Troubleshooting section

entitled, Checking or Resetting the
Circuit Breakers.

Troubleshooting (continued)

Problem

Compressor will not start.

Possible cause

High pressure switch has been tripped.

Circuit breaker has been tripped.

Loose wire connection or defective
start capacitor.

The actual “To Process” temperature is
below the setpoint.

Damaged or defective start capacitor.

Poor water flow.

Damaged or defective compressor.

Solution

Reset the High Pressure switch. See

Operation section entitled, Resetting
the High Pressure Switch.

Verify resistance to ground. Reset
breaker. See Troubleshooting section

entitled, Checking or Resetting the
Circuit Breakers.

Check wiring diagrams, see Appendix

H entitled, Electrical Schematic,

replace connections or capacitor.

Lower setpoint temperature value. See

Operation section entitled, Starting the
Chiller.

Contact Conair Service.

Check pump rotation.

Clean the pump strainer. See

Maintenance section entitled, Cleaning
the Pump Strainer.

Have a certified refrigeration
technician replace the compressor.

6-6 l Troubleshooting

NOTE:

Also, see
Troubleshooting section,
entitled, Troubleshooting,
“Chiller shuts down due
to a High Pressure switch
alarm” and “Chiller shuts
down due to a Low
Pressure switch”.

✐

Troubleshooting (continued)

Problem

Chiller shuts down due to a
High Pressure switch alarm.

Chiller shuts down due to a
Low Pressure switch.

Possible cause

Low air flow across the condenser.

Fan not operating.

High ambient temperature.

Insufficient clear space around unit.

Clogged air filter.

Attempting to operate the chiller with
process coolant below 45°F {7.2°C}.

Low refrigerant charge.

Poor heat transfer in the evaporator
tank due to a high percentage of glycol
to water.

Low flow through the evaporator due
to glycol foaming.

Low flow through the evaporator.

Faulty pump motor.

Clogged pump strainer.

Solution

Check for dirty condenser fins. Clean
as necessary. See Maintenance section

entitled, Cleaning the Air-cooled
Condenser.

Reset High Pressure switch. See

Operation section entitled, Resetting the
High Pressure Safety Switch.

Check for loose fan blade or
open/grounded motor winding.

Move the chiller to a lower ambient
temperature location.

Increase clearance around the chiller.

Replace filter. See Maintenance section

entitled, Cleaning the Air-cooled
Condenser.

Increase temperature setpoint above
45°F {7.2°C}. See Operation section

entitled, Starting the Chiller.

See Installation section entitled,
Checking the Refrigerant Charge.

Reduce the glycol mixture of the
process coolant. See Installation

section entitled, Filling the Chiller.

Replace the process coolant. See

Installation section entitled, Filling the
Chiller.

See Maintenance section entitled,
Cleaning the Brazed Plate Evaporator.

Contact Conair Service.

Clean or replace the strainer. See

Maintenance section entitled, Cleaning
the Pump Strainer.

6

Troubleshooting

Troubleshooting l 6-7

NOTE: The is a normal
shutdown for other
alarm conditions when
the chiller’s main power
has been switch off.

✐

Checking or Replacing the
Temperature Sensor

The EarthSmart ECM Series Chiller uses a RTD sensor to monitor the temperature
of the process coolant.

To check or replace an RTD sensor:

1 Disconnect and/or lockout the main power supply.

2 Locate the RTD sensor.

3 Check the sensor’s position and condition. Temperature readings will be

incorrect if the sensor is touching the wall of a pipe or if the sensor or wiring is
damaged. Sensor wires should be attached to the appropriate connection points
on the chiller’s control center.

4 To check with ohm meter, measure the resistance across the RTDs. The

resistance should be approximately 110 ohm at room temperature. See

Appendix F entitled, RTD Resistance Chart.

5 Remove the sensor from its housing using an appropriately-sized wrench.

6 Inspect the sensor for cleanliness. Replace if necessary with another sensor of

the same rating.

7 Replace the RTD, by wrapping the its threads with Teflon tape or pipe dope.

8 Re-insert the RTD into its housing, start by hand until its threads engage.

Tighten with an appropriately-sized wrench, do not over tighten.

Typical location of
the RTD at the
chiller’s evaporator.

IMPORTANT

: Always refer

to the wiring diagrams
that came with your
chiller to locate specific
electrical components.
Illustrations in the User
Guide are intended to be
representative only.

Replacement RTDs are
available from Conair.

Contact Conair Parts
[phone]
From outside of the
United States, call:
[phone]

6-8 l Troubleshooting

Troubleshooting l 6-9

Checking or Resetting the Circuit
Breakers

The EarthSmart ECM Series Chiller uses electrical circuit breaker to protect the
chiller from overloads or improper operating conditions.

To check or reset the chiller’s circuit breakers:

1 Disconnect and lockout the main power supply.

2 Remove the chiller’s top lid, by first removing both side panels and then the

four (4) retaining bolts that secure the chiller’s top lid.

3 Locate the appropriate circuit breaker(s), located behind the chiller’s

control panel. See the wiring diagrams that came with your chiller.

4 Check the circuit breaker(s) position and condition. The chiller will not

operate correctly if one or more circuit breakers have been tripped (facing
down).

5 Reset the circuit breaker(s), if necessary.

6 Replace the chiller’s side panels and then the top lid by replacing the four

(4) retaining bolts.

7 Reapply main power.

IMPORTANT

: Always refer

to the wiring diagrams
that came with your
chiller to locate specific
electrical components.
Illustrations in the User
Guide are intended to be
representative only.

Circuit Breakers

A-1 l Appendix

We’re Here to Help

Conair has made the largest investment in customer support in the plastics indus­try. Our service experts are available to help with any problem you might have
installing and operating your equipment. Your Conair sales representative also
can help analyze the nature of your problem, assuring that it did not result from
misapplication or improper use.

How to Contact Customer Service

To contact Customer Service personnel, call:

You can commission Conair service personnel to provide on-site service by
contacting the Customer Service Department.

Before You Call...

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

❒

Make sure you have all model, control type and serial numbers from the serial
tag, and parts list numbers for your particular equipment. Service personnel will
need this information to assist you..

❒

Make sure power is supplied to the equipment.

❒

Make sure that all connectors and wires within and between control systems
and related components have been installed correctly.

❒

Check the troubleshooting guide of this manual for a solution.

❒

Thoroughly examine the instruction manual(s) for associated equipment, especial­ly controls. Each manual may have its own troubleshooting guide to help you.

❒

Check that the equipment has been operated as described in this manual.

❒

Check accompanying schematic drawings for information on special considerations.

PARTS & SERVICE

U

S

8

0

0

4

5

8

1

9

6

0

I

N

T

E

R

N

A

T

I

O

N

A

L

+

1

8

1

4

4

3

7

6

8

6

1

Additional manuals and prints for
your Conair equipment may be
ordered through the Customer
Service or Parts Department for a
nominal fee. Most manuals can
be downloaded free of charge
from the product section of the
Conair website.
www.conairgroup.com

NOTE: Normal operating hours are 8:00 am - 5:00 pm (EST). After hours emergency

service is available at the same phone number.

✐

Appendix l A-2

Equipment Guarantee

Conair guarantees the machinery and equipment on this order, for a period as
defined in the quotation from date of shipment, against defects in material and
workmanship under the normal use and service for which it was recommended
(except for parts that are typically replaced after normal usage, such as filters,
liner plates, etc.). Conair’s guarantee is limited to replacing, at our option, the part
or parts determined by us to be defective after examination. The customer assumes
the cost of transportation of the part or parts to and from the factory.

Performance Warranty

Conair warrants that this equipment will perform at or above the ratings stated in
specific quotations covering the equipment or as detailed in engineering specifica­tions, provided the equipment is applied, installed, operated and maintained in the
recommended manner as outlined in our quotation or specifications.

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

• Inspect the equipment and perform alterations or adjustments to satisfy

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

• Replace the original equipment with other Conair equipment that will meet

original performance claims at no extra cost to the customer.

• Refund the invoiced cost to the customer. Credit is subject to prior notice by the

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

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

Warranty Limitations

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

B-1 l Appendix

Safety Adjustments

To ensure safe and efficient operation at lower setpoints, adjustments of the
low pressure switch from factory settings is required. The table below lists the
appropriate settings.

The low pressure switch serves as the mainline defense against freezing. It
shuts down the chiller if the coolant temperature ever decreases to its setting.

To adjust a mechanical low pressure switch:

1 Disconnect and lockout the main power supply.

2 Remove the chiller’s right-side panel, as viewed from the control.

3 Locate the low pressure switch within the top portion of the chiller’s cabinet.

4 Turn the low pressure cut-in and cut-out adjustment screws found on the

top of the low pressure switch, according the operating temperature located
on the chart above.

5 Replace the chiller’s right-side panel and reapply main power.

Operating Low Low

Temperature Cut In Cut Out

45°F 35# 25#
40°F 30# 20#
35°F 25# 16#
30°F 20# 12#

NOTE: For chiller operation

below 45°F {7.2°C}, the

chiller’s control must

be

configured properly. Contact

Conair Service.

✐

CAUTION: At any setpoint, the
possibility of freezing exists and
it is the operator’s responsibility
to take necessary action to
prevent freezing at all times.

NOTE: The high and low pres-

sure switches are enclosed

inside the same module.

✐

IMPORTANT: A correct mixture of

glycol and water must be used as

process coolant for operation below

45°F {7.2°C}.

See Installation sec-

tion entitled, Filling the Chiller.

Cut-out adjustment

Cut-in adjustment

Appendix l C-1

Water Quality Control

Insufficient or improper water treatment can damage the EarthSmart ECM Chiller.
A certified water treatment specialist should be consulted for your particular
application. It is the owner’s responsibility to prevent damage from foreign
material or inadequate water treatment.

The two main points to consider for water treatment in chillers are:

• Corrosion

• Organism growth

Proper chemical treatment will control pH levels and algae growth.

D-1 l Appendix

Chiller Capacity and Derate Chart

If operation of the chiller is less than 45°F {7.2°C}, a glycol and water mixture
is required. See Operation section entitled, Filling the Chiller.

Ambient conditions affect air-cooled chiller operation and capacity. Standard
rating is at 95°F {35°C} entering air temperature. For ambient air conditions
greater than 95°F {35°C}, chiller derating will occur.

Standard chiller rating is 50°F {10°C} leaving water. For all other temperature
settings, output tonnage is altered as follows:

Output Full Available %
Temperature °F {°C} Capacity

60°F {15.5°C} 105%

50°F {10°C} 100%
45°F {7.2°C} 90%
40°F {4.4°C} 80%
35°F {1.6°C} 70%

30°F {-1.1°C} 60%
25°F {-3.8°C} 50%
20°F {-6.7°C} 40%

NOTE: Models must be positioned so that the condenser air inlet is no warmer than 95°F

{35°C} and the condenser air outlet is not blocked or restricted in any way.

✐

NOTE: Locate models away from heat producing equipment. These items will affect ambi-

ent air conditions and the performance of the chiller.

✐

NOTE: For chiller operation

below 45°F {7.2°C}, the

chiller’s control must

be

configured properly. Contact

Conair Service.

✐

IMPORTANT: A correct mixture of

glycol and water must be used as

process coolant for operation below

45°F {7.2°C}.

See Installation sec-

tion entitled, Filling the Chiller.

Appendix l E-1

Pressure-Temperature Chart for
R-134A Refrigerant

Refrigerant Pressure (PSIG)

5
10
15
20
25
30
35
40
45
50
55
60
65
70
75
80
85
90
95

100
105
110
115
120
125
130
135
140
145
150
155
160
170
180
190
200
210
220
230

Saturated Temperature

-3

°F {-19.4°C}

7°F {-13.9°C}
15°F {-9.4°C}
22°F {-5.5°C}
29°F {-1.6°C}
35

°F {1.6°C}

40°F {4.4°C}

45°F {7.2°C}
50°F {10°C}
54°F {12.2°C}
58°F {14.4°C}
62°F {16.7°C}
66°F {18.9°C}
69°F {20.5°C}
73°F {22.7°C}
76°F {24.4°C}
79°F {26.1°C}
82°F {27.7°C}
85°F {29.4°C}
88°F {31.1°C}
90°F {32.2°C}
93°F {33.8°C}
96°F {35.5°C}
98°F {36.6°C}
100°F {37.7°C}
103°F {39.4°C}
105°F {40.5°C}
107°F {41.6°C}
109°F {42.7°C}
112°F {44.4°C}
114°F {45.5°C}
116°F {46.6°C}
120°F {48.8°C}
123°F {50.5°C}
127°F {52.7°C}
130°F {54.4°C}
134°F {56.6°C}
137°F {58.3°C}
140°F {60°C}

NOTE: These pressure/
temperature relationships are in
an “At-Rest”, saturated
condition. For example, if the
unit has been in a warehouse at
40°F {4.4°C} and it is brought
to a room where it is 80°F
{26.7°C}, it may require a few
hours for the unit to warm and
the pressure to rise to the
surrounding ambient conditions.

✐

F-1 l Appendix

RTD Resistance Chart

You can use the following chart to determine if you need to replace your RTD.

Appendix l G-1

Overhead Plumbing Details

Overhead piping installations above process connections require installing a check
valve in the “To Process” line and a 12 inch {305 mm} riser with a check valve and
vacuum break in the “From Process” line to prevent siphoning when shutting down
the chiller. Install a vent tube at 12 inches {305 mm} above the highest system point
to prevent over pressurization. Maximum height of piping above process connections
is 25 ft {7.6 m}.

back view

Internal vent; 1 ft above
highest water level

vacuum break

check valve

12 in. riser

From process

To process

H-1 l Appendix

Electrical Schematic

9.00

9.00

8.00

8.00

4.04

4.04

1TC

1TC

1ENC

1ENC

1CAB

1CAB

1SW

1SW

2CB

2CB

1CB

1CB

1TB

1TB

1GB

1GB

1

2

2

2

2

3

4

6

7

7

8

9

10

10

2ENC

2ENC

1TC

1TC

1SW

1SW

7.88

7.88

1PL

1PL

2PL

2PL

3PL

3PL

2CAB

2CAB

4PL

4PL

5PL

5PL

7PL

7PL

6PL

6PL

Appendix l I-1

Control Setup

1/32 DIN Watlow SD controller Setup Sheet

Enter the following parameters

Menu Parameter Description Setting
Set Up Page Sen Input sensor type RTD
up & down for C-F Temperature Units (degrees) F
3 seconds S.dec Temperature Decimal Places 0

IS.en Infosense no
SP.Lo Set Point Low Limit 40.0
SP.hi Set Poing High Limit 65
Ftr.e Input Filter Both
Flt.r Filter value - Seconds 5
Ot1 Output 1 function heat
Ctr1 Control Method 1 ftb
Ftb1 Cycle time 1 10
PL 1 Power Limit 1 100%
PSL1 Output Power Limit Sacle Low 1 0%
PSH1 Output Power Limit Sacle High 1 90%
nLF1 Output Non-Linear Function 1 Off
Ot2 Output 2 Function - SP devaition dE.AL
hys2 Alarm Hysteresis 2 1.5F
Lgc2 Alarm relay state on alarm - open Al o
Lat2 Alarm 2 latching nLat
dSP2 Alarm 2 Message on
ACLF AC line frequency 60
Unit Units of Measurement SI
I.Err Input error latching nLat
FAIL Input Error Failure Mode bPLS
Man Manual Error Level 0%
dSP Active Displays nor
rP Ramping Mode off
LOC Security Lockout 3

Programming Adv and INF keys 6 seconds

P1 Temperature Units - C-F F
P2 Low Temp Dev. alarm - A2.Lo -4
P3 High Temp dev Alarm - A2.HI 20
P4 Proportional Band Hot Gas - pb.ht 3
P5 Intergral Hot Gas - It.ht 3.4
P6 Derivative - dE.ht 0.1

Plumbing Schematic

FROM PROCESS

1

2

"

TO PROCESS

1

2

"

LEVEL

WATER

TANK

1

PSL

FS

1

EVAPORATOR

(1/4" schraeder valve)

PI

1

RANGE= 40 TO 65 °F

TAHH

1

S

TE

1

TALLTIC

11

S

TO PROCESS

TEMP

(1/4" gauge port)

TXV

FILTER/DRYER

SIGHT GLASS

NOTES:

K OR L-TYPE COPPER TUBING TO BE USED FOR REFRIGERANT PIPING1.

PRESSURE TESTING, EVACUATION AND REFRIGERANT CHARGING OF THE 2.

CHILLER SHALL BE PERFORMED PER SECTION 3 OF THE CONAIR CHILLER

TEST STAND MANUAL.

SV-2 TO BE LOCATED ABOVE COMPRESSOR DISCHARGE.3.

VAPOR CHARGING & EVACUATION VALVE ON SUCTION LINE NOT REQUIRED 4.

IF SUCTION VALVE HAS A SERVICE PORT.

1/2" FILL/DRAIN

(HOSE BIBB)

VENT 3/8"

RECEIVER

0-150 PSI GAGE

XX

X

S

DESCRIPTION

BY

DATE

APP

ECN

REV

01

WDH

09/12/07

DEW

PROTOTYPE

02

DEW

REVISED

11/27/07

DEW

±

0.015

±

1/2

°

125

±

0.015

±

1/32

XX:

FINISH:

FORMED SHEETMETAL:

ANGLES:

FRACTIONS

DECIMAL MACHINING:

The Conair Group Inc.

Pittsburgh, PA 15202

One Conair Drive

ACAD

XXX:

PORTABLE CHILLER,AIRCOOLED

SINGLE PUMP, ENHANCED

MACHINING TOLERANCES:

01

REV:

1 OF 1

SHEET:

DWG NO.:

DRAWN BY:

DATE:

ECA.5 P&ID

±

0.005

04/02/08

WJS

DXF

CONDENSER FAN

SV-1

LIQUID LINE VALVE

SV-2

HOT GAS BYPASS

SEE NOTE 3

LINE SIZE REDUCTION

PRESSURE RELIEF VALVE

Thermostatic Expansion Valve

INLINE INSTRUMENT w/ TAG NUMBER

STRAINER

SOLENOID VALVE

Hand Valve

LEGEND

BYPASS

3

8

"

CUT OUT AT

230

PSIG

ON RISE MANUAL RESET

PSV SET AT

250

PSIG

CUT OUT AT

25

PSIG ON FALL

PSIG ON RISE35

CUT IN AT

PSIG ON RISE

1

PSH

200

PSIG ON FALL125

CUT IN AT

CUT OUT AT

PSH

2

(1/4" schraeder valve)

1

4

" OD TUBE

1

4

" OD TUBE

1

4

" OD TUBE

1

4

" OD TUBE

3

8

" OD TUBE

3/8" OD TUBE

REFRIGERATION ISOLATION VALVE

PSIG

PSV SET AT

50

1

8

" FPT

3

8

"

3

8

"

3

8

"

3

8

"

3

8

"

1

4

"

1

4

"

10 GALLON

3

8

" OD TUBE

1

4

"

END OF CONDENSING UNIT

1

4

"

J-1 l Appendix