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
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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
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