Conair VL User Manual

Portable Chillers

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Parts and Service

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The Conair Group, Inc.
One Conair Drive
Pittsburgh, PA 15202
Phone: [phone]
Fax: [phone]

VL Series, 0.25 to 1.5 ton models

UGH020/0301

Installation

Maintenance

Operation

Troubleshooting

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

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

Date:

Manual Number: UGH020/0301

Serial number(s):

Model number(s):

DISCLAIMER: The Conair Group, Inc., shall not be liable for errors

contained in this User Guide or for incidental, consequential dam­ages in connection with the furnishing, performance or use of this
information. Conair makes no warranty of any kind with regard to
this information, including, but not limited to the implied warranties
of merchantability and fitness for a particular purpose.

Please record your

equipment’s model and

serial number(s) and

the date you received it

in the spaces provided.

Copyright 2001 All rights reserved

THE CONAIR GROUP, INC.

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UGH020/0301 VL Series Portable Chillers, 0.25 to 1.5 Tons

TABLE OF CONTENTS

1.0 GENERAL 5

1.1 Unit location 6

1.2 Efficiency 6

1.3 Safety 6

1.4 Clean air act 6

1.5 Miscellaneous 7

2.0 INSTALLATION 9

2.1 General 10

2.2 To and From process connections 10

2.3 Unit drain 11

2.4 Air-cooled condenser 11

2.5 Electrical connection 12

3.0 OPERATIONS SEQUENCE 13

3.1 General 14

3.2 Start up / operations procedure 14

3.3 Instrument operation 15

3.4 Shut down / disconnect sequence 18

4.0 TROUBLESHOOTING 19

4.1 Unit will not start 20

4.2 Pump will not start 20

4.3 Compressor will not start 20

4.4 Unit shuts down on high pressure switch 20

4.5 Unit shuts down on low pressure switch 20

5.0 MAINTENANCE 23

5.1 Warranty service procedure 24

5.2 Periodic preventative maintenance 24

5.3 Special maintenance 25

5.4 Pump repair 25

6.0 COMPONENTS 27

6.1 Water system 28

6.2 Refrigeration system 28

7.0 RELATED DRAWINGS 29

7.1 Electrical (typical) 30

7.2 Circuit schematic 31

8.0 APPENDIX 33

8.1 Specifications 34

8.2 Operations below 48°F 35

8.3 Water quality control 37

8.4 Inhibited propylene glycol 37

8.5 Chiller capacity and derate chart 39

8.6 Pressure - temperature chart for R-22 40

8.7 Engineering formulas 41

8.8 Spare parts list 42

VL Series Portable Chillers, 0.25 to 1.5 Tons UGH020/0301

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UGH020/0301 VL Series Portable Chillers, 0.25 to 1.5 Tons

1.0 GENERAL

1.1 UNIT LOCATION

1.2 EFFICIENCY

1.3 SAFETY

1.4 CLEAN AIR ACT

1.5 MISCELLANEOUS

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VL Series Portable Chillers, 0.25 to 1.5 Tons UGH020/0301

1.1 UNIT LOCATION

A. The unit is designed for indoor use only. For most efficient

operation, locate the chiller in a clean, dry and well ventilated
environment.

B. The unit has an air-cooled refrigerant condenser. For air-cooled

condensers, a motor driven fan generates air flow through the
condenser to remove heat from the refrigerant system. The air­cooled condenser on the unit will discharge a maximum of 15,000
BTUs per hour per ton of cooling.

C. The unit must have a minimum entering air temperature of 60°F

and a maximum entering air temperature of 95°F for efficient
operation.

D. The unit must have a minimum of two feet clearance at the air

intake and six feet at the exhaust air discharge.

E. If the operator has any questions concerning the location and

operation of the unit, contact the Conair service department at
800-458-1960.

1.2 EFFICIENCY

A. Long term efficiency of operation is largely determined by proper

maintenance of the mechanical parts of the unit and the water
quality. Conair recommends filtering where required to prevent
solids from plugging critical parts (pumps, heaters, seals for
example). Conair highly recommends the services of a competent
water treatment specialist be obtained and his recommendations
followed. Conair accepts no responsibility for inefficient operation,
or damage caused by foreign materials or failure to use adequate
water treatment.

1.3 SAFETY

A. It is important to become thoroughly familiar with this manual and

the operating characteristics of the unit.

B. It is the owner’s responsibility to assure proper operator training,

installation, operation, and maintenance of the unit.

C. Observe all warning and safety placards applied to the unit. Failure

to observe all warnings can result in serious injury or death to the
operator and sever mechanical damage to the unit.

1.4 CLEAN AIR ACT

A. The unit contains HCFC-22 (chlorodifloromethane). This is a class 2

substance.

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UGH020/0301 VL Series Portable Chillers, 0.25 to 1.5 Tons

B. Please be aware that effective July 1, 1992, it is unlawful for any

person in the course of maintaining, servicing, repairing, or
disposing of refrigeration equipment to knowingly vent or
otherwise dispose of any class 2 substance used as a refrigerant in
the manner which permits such substance to enter the
environment.

C. De minimis releases associated with good faith attempts to

recapture, reclaim, or recycle such substance shall not be subject to
the prohibition set forth in the preceding paragraph.

1.5 MISCELLANEOUS

A. The purpose of the unit is to circulate temperature stabilized fluid

through your process, resulting in process temperature control.

B. The ability of the unit to maintain process temperature control is

significantly affected by the method of installation.

C. If the operator has any questions concerning the location and

operation of the unit, please contact the Conair service at
800-458-1960 or 814-437-6861

Illuminated ‘On’ Switch

Controller

Air Cooled Condenser

Condensing Fan

Electrical Panel

Pump

Reservoir

Thermocouple

Bypass Valve

Refrigerant
Sight Glass

Filter-Drier

Power Cord

Refrigerant
Safety Switches

Liquid Receiver

Caster

VL Series Portable Chillers, 0.25 to 1.5 Tons UGH020/0301

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UGH020/0301 VL Series Portable Chillers, 0.25 to 1.5 Tons

2.0 INSTALLATION

2.1 GENERAL

2.2 TO AND FROM PROCESS CONNECTIONS

2.3 UNIT DRAIN

2.4 AIR COOLED CONDENSER

2.5 ELECTRICAL CONNECTION

2.1 GENERAL

A. All process piping materials (such as hose, rigid piping, valves or

filters) used in process water piping circuitry must be rated for
100°F minimum temperature and 100 PSI minimum pressure.

B. All such materials must have the equivalent or larger diameter of

the particular process connection that length of process water
piping is connected to.

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VL Series Portable Chillers, 0.25 to 1.5 Tons UGH020/0301

2.2 TO AND FROM PROCESS CONNECTIONS

A. Connect the chiller’s “to process” connection to the “water in”

manifold on the mold or process.

B. Connect the chiller’s “from process” connection the “water out”

manifold at the mold or process.

C. 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.

D. Valves and filters may be installed in the process water piping

circuitry to facilitate service and maintenance provided that such
devices maintain the full inside diameter of the process connection.
If installed, all such devices must be open and clean during unit
operation.

To process connection:

connect to “water in” on process manifold

From process connection:

connect to “water out” on process manifold

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UGH020/0301 VL Series Portable Chillers, 0.25 to 1.5 Tons

2.3 DRAIN CONNECTION:

A. The unit is supplied as standard with a ProCon type pump. In some

cases, it may be necessary to drain the unit. This is done by
removing the pump volute plug in the pump assembly.

B. Note that if chemical treatment of process fluid or additives are use,

drainage shall be done according to local codes.

C. It is important to note that drainage procedures must be done prior

to shipment or outdoor storage or the unit. If not, freezing damage
can occur.

2.4 AIR COOLED CONDENSER

A. Air-cooled condenser require ambient air temperatures between

60°F and 95°F for efficient operation. Operating above 95°F may
result in elevated condensing pressures and eventual shut-down on
the high pressure safety switch. Check with the Conair service
department for more information on operating with ambient air
temperatures above 95°F or below 60°F.

B. 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.

C. A free air space of at least four (4) feet is required at the condenser

intake and four (4) feet at the condenser discharge to allow for
proper air flow.

D. At full load, this chiller will discharge approximately 15,000 BTU/hr

per hour per ton of cooling.

Thermocouple

Motor

Pump

Drain plug

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VL Series Portable Chillers, 0.25 to 1.5 Tons UGH020/0301

2.5 ELECTRICAL CONNECTION

A. NEMA 1 MODELS

1. Electrical power supply requirements for Nema 1 units

(figure 2.5A) are identified on the equipment data plate.
Verify that available voltage supply is the same as the unit’s
voltage requirements. WARNING: Do not connect the

unit to a voltage supply source not equal to the unit’s
voltage requirements as specified on the unit’s data
plate. Use of incorrect voltage will void the unit’s
warranty and cause a significant hazard that may result
in serious personal injury and unit damage.

2. A factory supplied, four conductor cable is installed for

connection to a customer supplied fused power disconnect
device. The fused disconnect device shall be sized and
installed according to the unit’s power supply requirements
and local electrical codes.

C. CONTROL CIRCUIT WIRING

1. The unit’s supplied control circuit is indicated in the

electrical diagrams. The control circuit is supplied by the
factory installed transformer.

D. GENERAL

1. Make certain all ground connections to the unit are

properly affixed.

2. Make certain power conductor, disconnect device, and
fusing are properly sized according to the unit’s power
supply requirements.

3. Make certain all electrical connections are tightly affixed.
Any loose wiring connections must be tighten before
engaging the power supply.

4. Make certain no moisture or standing water is present
inside the electrical cabinet.

Microprocessor

controller

Illuminated on/off

switch

Motor starter

Transformer

3.0 OPERATIONS

3.1 GENERAL

3.2 START UP/OPERATIONS PROCEDURE

3.3 INSTRUMENT OPERATION

3.4 SHUT DOWN/DISCONNECT SEQUENCE

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UGH020/0301 VL Series Portable Chillers, 0.25 to 1.5 Tons

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VL Series Portable Chillers, 0.25 to 1.5 Tons UGH020/0301

3.1 GENERAL

A. Failure to follow the factory required operation procedures may

adversely affect the unit’s ability to control process temperature and
may create a hazardous operating condition which may result in
unit damage and serious operator injury or death.

B. The Operations segment of this manual is outlined below:

3.2 Machine start-up/operations procedure - follow this

segment to start the unit after the initial installation or to
restart the unit after reinstallation to the same or different
process. This section includes information on system fill,
electric motor phasing (pump rotation) and process flow
adjustments.

3.3 Instrument - follow this segment to start up and operate
the instrument controller. This section includes information
on automatic and manual venting, setpoint selection and
adjustment, and feature explanations.

3.4 Shut down procedure - follow this segment to shut down
the unit. This segment includes information on system cool
down, shut down, electrical power supply precautions, and
disconnection from system.

3.2 START UP/OPERATIONS PROCEDURE

A. SYSTEM FILL

1. The unit has an internal reservoir which must be filled and

maintained for proper operation.

2. Conair recommends the addition of 20% inhibited
propylene glycol to the process fluid. This should help
prevent the process fluid from freezing and internal
components from rusting. A biocide must be added to the
water to prevent organism growth in the chilled water
system. See water treatment section in section 8 of this
manual for more information.

3. Remove the top panel
to access the reservoir.
Add fluid directly to the
reservoir tank. Please
note, when the pump is
first started, and after
the process lines are
filled and entrained air
is purged, additional
fluid may be required to
restore the reservoir to
the correct level.

Reservoir