Conair VL Series, VLA-7.5, VLA-10, VLA-15, VLA-20 User Manual

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Installation

Maintenance

Operation

Troubleshooting

Portable Chillers

VL Series Air-Cooled and Water-Cooled with Capacities from 2 to 40 tons

The Conair Group, Inc. One Conair Drive Pittsburgh, PA 15202 Phone: (412) 312-6000 Fax: (412)-312-6227

UGH021/0301

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: UGH021/0301

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.

THE CONAIR GROUP, INC.

UGH021/0301 VL Series Portable Chillers, 2 to 40 Tons

Page: 3

TABLE OF CONTENTS

1.0 GENERAL 5

1.1 Introduction 6

1.2 Unit location for air cooled models 6

1.3 Unit location for water cooled models 6

1.4 Efficiency 6

1.5 Safety 7

1.6 Clean air act 7

1.7 Miscellaneous 7 Chiller features identified 8

2.0 INSTALLATION 9

2.1 General 10

2.2 To and From process connections 10

2.3 Water supply connection 11

2.4 Air cooled condenser 11

2.4 Water cooled condenser 13

2.5 Electrical connection 13

3.0 OPERATIONS 17

3.1 General 18

3.2 Start up/operations procedure 18

3.3 Instrument operation 23

3.4 Shut down procedure 26

4.0 TROUBLESHOOTING 27

4.1 Sensors 28

4.2 Process pump 28

4.3 Compressor 28

4.4 Blower/fan 28

4.5 Low flow 28

4.6 High Pressure 29

4.7 Low pressure 29

4.8 Freezestat 29

4.9 Oil pressure 30

4.10 Crankcase heater 30

4.11 Electronics 30

5.0 MAINTENANCE 31

5.1 Warranty service procedure 32

5.2 Periodic preventative maintenance 32

5.3 Special maintenance 33

5.4 Solenoid valve service 34

5.5 Pump seal service 36

5.6 Checking the refrigerant charge 39

5.7 Proper cleaning procedure for brazed plate evaporators 40

6.0 COMPONENTS 43

6.1 Water system 44

6.2 Refrigeration system 44

Page: 4

7.0 RELATED DRAWINGS 47

7.1 VLA-5/7.5/10 mechanical schematic 48

7.2 VLA-15/20/25/30 mechanical schematic 49

7.3 VLA-5 physical 50

7.4 VLA-7.5/10 physical 51

7.5 VLA-15/20/25/30 physical 52

7.6 Duct schematic for air cooled chillers 53

7.7 VLA-5/ 7.5/ 10 electrical 54

7.8 VLA-15/ 20/ 25/ 30 electrical 55

7.9 VLW-5/7.5/10 ton mechanical schematic 56

7.10 VLW-15/20/25/30 ton mechanical schematic 57

7.11 VLW-5/7.5/10 physical 58

7.12 VLW-15/20/25/30 ton physical 59

7.13 VLW-5/ 7.5/ 10 ton electrical 60

7.14 VLW-15/ 20/ 25/ 30 ton electrical 61

8.0 APPENDIX 63

8.1 Specifications 64

8.2 Operations below 48°F 66

8.3 Water quality control 68

8.4 Inhibited propylene glycol 68

8.5 Maintaining proper water flow 70

8.6 Low flow bypass circuits 71

8.7 Overhead piping kit 72

8.8 Chiller capacity and derate chart 73

8.9 Pressure-temperature chart for R-22 refrigerant 74

8.10 Engineering formulas 75

8.11 Spare parts list- water-cooled models 76

8.12 Spare parts list- air-cooled models 77 A-1 Service Information 79 A-2 Warranty information 80

UGH021/0301 VL Series Portable Chillers, 2 to 40 Tons

Page: 5

1.0 GENERAL

1.1 INTRODUCTION

1.2 UNIT LOCATION FOR AIR COOLED MODELS

1.3 UNIT LOCATION FOR WATER COOLED MODELS

1.4 EFFICIENCY

1.5 SAFETY

1.6 CLEAN AIR ACT

1.7 MISCELLANEOUS

Page: 6

VL Series Portable Chillers, 2 to 40 Tons UGH021/0301

1.1 INTRODUCTION

A. This manual covers most ‘VL’ series portable chiller models. Most

‘VL’ series portable chillers are basically identical with exception of the type of condenser (air cooled or water cooled).

B. All instructions in this manual apply to most ‘VL’ series portable

chiller models regardless of the type of condenser or instrumentation. Specific instructions relating only to air cooled condensers, water cooled condenser, or instrumentation are identified and should be noted by the operator.

C. When calling for assistance from the Conair Service Department, it

is important to know the model and serial number of the particular unit. The model number encodes critical unit information which is helpful in any attempt to troubleshoot operating difficulties. The serial number allows the service team to locate manufacturing and testing records which can have additional information relating to a particular unit.

1.2 UNIT LOCATION FOR AIR COOLED MODELS

A. The ‘VL’ air cooled portable chiller is designed for indoor use only.

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

B. The ‘VL’ air cooled portable chiller has an air cooled refrigerant

condenser. For air cooled condensers, a motor driven fan (on models from 2 to 10 tons) or a centrifugal blower (on models from 15 to 30 tons) generates air flow through the condenser to remove heat from the refrigerant system. The air cooled condenser on the ‘VL’ portable chiller will discharge a maximum of 15,000 BTU’s per hour per ton of cooling.

C. The ‘VL’ air cooled portable chiller must have a minimum entering

air temperature of 60°F and a maximum entering air temperature of 95°F for efficient operation.

D. The ‘VL’ air cooled portable chiller must have a minimum of two

feet clearance at the air intake and six feet at the vertical exhaust air discharge.

1.3 UNIT LOCATION FOR WATER COOLED MODELS

A. The ‘VL’ water cooled portable chiller is designed for indoor use

only. For most efficient operation, locate the chiller in a clean, dry and well ventilated environment.

1.4 EFFICIENCY

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

maintenance of the mechanical parts of the unit and the water

UGH021/0301 VL Series Portable Chillers, 2 to 40 Tons

Page: 7

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.

1.5 SAFETY

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

the operating characteristics of the Conair ‘VL’ series portable chiller.

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

installation, operation, and maintenance of the Conair ‘VL’ series portable chiller.

C. Observe all warning and safety placards applied to the chiller.

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

1.6 CLEAN AIR ACT

A. The ‘VL’ series portable chiller contains HVLC-22

(chlorodifloromethane). This is a class 2 substance.

B. 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 atmosphere.

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.

1.7 MISCELLANEOUS

A. The ‘VL’ series portable chiller is designed to circulate temperature

stabilized fluid through the process resulting in process temperature control.

B. The ability of the ‘VL’ series portable chiller to maintain process

temperature control is significantly affected by the method of installation as outline in section 2 of this manual.

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

operation of the ‘VL’ series portable chiller, contact the Conair Service Department at 800-458-1960 or 814-437-6861.

Page: 8

VL Series Portable Chillers, 2 to 40 Tons UGH021/0301

To Process Connection

From Process

Connection

Hot Gas

Bypass

Valve

VLA-10

pictured

Compressor

Expansion

Valve

Liquid Line

Solenoid

Refrigerant Sight Glass

Insulated

Fiberglass

Reservoir

Centrifugal

Pump

Electrical

Cabinet

Galvanized

Steel Frame

Fan Motor

Air Cooled

Condenser

Fiberglass Fan Shroud

Caster

Filter-Drier

To Process Connection

From Process

Connection

VLW-10

pictured

Condenser Supply

Condenser

Condenser Return

Condenser

Expansion

Valve

Liquid Line

Solenoid

Hot Gas

Bypass Valve

Filter-Drier

(not visible in

photograph)

Refrigerant Sight Glass

Insulated

Fiberglass

Reservoir

Centrifugal

Pump

Electrical

Cabinet

Galvanized

Steel Frame

Caster

Compressor

Condenser

UGH021/0301 VL Series Portable Chillers, 2 to 40 Tons

Page: 9

2.0 INSTALLATION

2.1 GENERAL

2.2 TO AND FROM PROCESS CONNECTIONS

2.3 WATER SUPPLY CONNECTION

2.4 AIR COOLED CONDENSER

2.5 WATER COOLED CONDENSER CONNECTION

2.6 ELECTRICAL CONNECTION

Page: 10

VL Series Portable Chillers, 2 to 40 Tons UGH021/0301

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.

2.2 TO AND FROM PROCESS CONNECTIONS

(see figures 2.2A & 2.2B)

A. Connect the ‘TO PROCESS’ to the ‘water in’ manifold on the mold

or process.

B. Connect the ‘FROM PROCESS’ port to the ‘water out’ port on the

process manifold.

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

Condenser water in

connection:

connect to tower or city water supply

Condenser water out

connection:

connect to tower or city water return

Water supply connection:

(not shown on this unit)

connect to plant’s city water source

Figure 2.2A

Typical process connections for water cooled chiller

UGH021/0301 VL Series Portable Chillers, 2 to 40 Tons

Page: 11

To process connection:

connect to “water in” on process manifold

From process connection:

connect to “water out” on process manifold

Water supply connection:

(not shown on this unit)

connect to city water source

Figure 2.2B

Typical process connections for air cooled chiller

2.3 WATER SUPPLY CONNECTION

A. The automatic water supply make-up system continually monitors

the reservoir tank and fills it when needed. Connect as follows:

1. Connect the chiller’s ‘WATER SUPPLY’ port to the plant’s

city water source.

2. Minimum water supply pressure requirement is identified

on the equipment data plate. This is normally 20 psi.

3. Be certain to use a water supply line equipped with a back

flow prevention device to prevent contamination of potable water.

2.4 AIR COOLED CONDENSER

A. Air cooled condensers require ambient air temperatures between

60°F and 95°F for efficient operation. Operating above above 95°F may result in elevated condensing pressures and eventual shutdown on the high pressure safety switch. In such cases, a water assist unit may be necessary for operations. Air temperatures below 60°F may result in below normal condensing pressures and poor condensing. In such cases, a low-ambient damper assembly is required. Check with the Conair service department for more information on operating with ambients air temperatures above 95°F or below 60°F.

Page: 12

VL Series Portable Chillers, 2 to 40 Tons UGH021/0301

B. Air flow is generated by the motor

driven fans (figure 2.4A) or centrifugal blowers (figure 2.4B). Air flow is from the outside of the chiller, through the condenser and exhausted through the top of the unit. On centrifugal blowers models, exhaust air can be ducted outside of the plant’s interior environment. Special duct work is required and a HVAC contractor should be consulted for sizing and material specifications. Exhaust air can not be ducted on motor driven fan models.

C. A free air space of at least two (2)

feet is required at the condenser intake and six (6) feet at the condenser discharge to allow for proper air flow.

D. At full load, the chiller will discharge

approximately 15,000 BTU’s per hour per ton of cooling.

E. On blower units, air discharge

duct work should be sized by a qualified HVAC engineer. Sizing shall be according to rated VLM at the static pressure of .90 inches of water. See figure 2.4C at right.

F. On blower units, a damper

control assembly is required in low ambient temperature areas or when outdoor air make-up is used. The assembly works in conjunction with refrigerant head pressure to regulate air flow to maintain proper refrigerant head pressure when condenser intake air temperature will be less than 60°F. See figure 2.4D to the right.

Figure 2.4C

Figure 2.4D

Figure 2.4A

Typical fan assembly

Figure 2.4B

Typical blower assembly

MODEL CFM

VLA-15 15,000 VLA-20 20,000 VLA-25 25,000 VLA-30 30,000

CFM RATINGS

Damper assembly

1/4" copper line connection

Angle valve and cap

Punch hole in top panel

1/4" Copper line

Liquid receiver (located inside chiller on base)

UGH021/0301 VL Series Portable Chillers, 2 to 40 Tons

Page: 13

2.5 WATER COOLED CONDENSER CONNECTION

A. Connect the ‘CONDENSER WATER

IN’ port to the plant’s city water

supply or tower system supply.

1. Required consumption from

a city water source is 1.5 gpm at 65°F per ton of rated capacity.

2. Required consumption for a

tower water source is 3 gpm at 85°F per ton of rated capacity.

B. Connect the chiller’s ‘CONDENSER

WATER OUT’ port to the plant’s

drain or tower system return.

1. Note: if dumping to the

plant’s open drain, drainage shall be done according to local codes.

C. The pressure differential requirement

between the condenser “water in” and the condenser “water out” lines must be 30 psi for adequate efficiency.

D. The installation of a strainer in the condenser “water in” line is

recommended. This removes solids from the water supply and serves to protect the water saver (regulator) valve.

E. An optional water saver (regulator) valve may be installed in the

condenser “water in” line. During winter months, or cold seasons, the valve will throttle the water flow through the condenser. The amount of flow is based on the refrigerant head pressure and the regulator will modulate the valve’s orifice to maintain a head pressure of 210 psig for best efficiency.

2.6 ELECTRICAL CONNECTION

A. NEMA 1 MODELS

1. Electrical power supply requirements for Nema 1 units are

identified on the equipment data plate. Determine the plant’s voltage supply is the same as the unit’s voltage requirements. WARNING: Do not connect the unit to a

voltage supply 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

Figure 2.5A

Condenser connections 30 ton unit - optional regulator valve shown

Figure 2.5B

Condenser connections 10 ton unit- optional regulator valve shown

Page: 14

VL Series Portable Chillers, 2 to 40 Tons UGH021/0301

cause a significant hazard that may result in serious personal injury and unit damage.

2. A customer supplied, four conductor cable is required for

connection to a customer supplied fused disconnecting means. The fused disconnecting means shall be sized and installed according to the unit’s power supply requirements and local electrical codes. See figure 2.5A (next page) for details on water cooled power cable routing.

3. Connect the four conductor power cable to power entry terminal block on the unit’s electrical panel. Then connect the power cable to the fused disconnect switch.

B. NEMA 12 MODELS

1. NEMA 12 units are constructed with a dust tight electrical

enclosure and branch circuit fusing. Electrical power supply requirements are identified on the equipment data plate. Determine the plant’s 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. Appropriate conduit and fittings should be selected which

will maintain the integrity of the cabinet.

3. Supply a power conductor sized according to the unit’s power supply requirements. Connect the power conductor to the unit’s power supply entry terminal block or the fused disconnect switch. Some Nema 12 models may be supplied with an optional disconnect switch. The owner supplied fused disconnecting means 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 110 volt, 1 phase, 60

cycle. The control circuit is supplied by the factory installed transformer. An inline control circuit fuse is provided.

D. GENERAL

1. Make certain all ground connections to the unit are

properly affixed.

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

UGH021/0301 VL Series Portable Chillers, 2 to 40 Tons

Page: 15

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 (figure 2.5B).

Refrigerant High

Pressurestat

Refrigerant Low

Pressurestat

Fuse Block

Transformer

Power Entry

Freezestat

Cabinet Door

Figure 2.6B Typical electrical cabinet detail.

Motor Starter

Overload Relay

Compressor Starter

Figure 2.6A

5 THRU 10 TON MODELS

ELECTRICAL CABINET

MICROPROCESSOR

CONTROLLER

5 THRU 10 TON MODELS

WATER COOLED

ROUTE POWER CORD

OUT OPEN BACK OF UNIT

TO DISCONNECT

ELECTRICAL CABINET

MICROPROCESSOR

CONTROLLER

WATER COOLED

15 THRU 30 TON MODELS

TO DISCONNECT

ROUTE POWER CORD

OUT OPEN BACK OF UNIT

VL Series Portable Chillers, 2 to 40 Tons UGH021/0301

Page: 16

THIS PAGE INTENTIONALLY BLANK

UGH021/0301 VL Series Portable Chillers, 2 to 40 Tons

Page: 17

3.0 OPERATIONS

3.1 GENERAL

3.2 START UP/OPERATIONS PROCEDURE

3.3 INSTRUMENT/OPERATION

3.4 SHUT DOWN PROCEDURE

Page: 18

VL Series Portable Chillers, 2 to 40 Tons UGH021/0301

3.1 GENERAL

A. Failure to follow the factory required operations procedure may

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

B. IMPORTANT: each chiller is equipped with a crankcase heater on

the compressor. While the compressor is idle, the crankcase heater prevents freon vapor from migrating to and condensing in the compressor crankcase. If freon is allowed to condense in the crankcase, it can be drawn into the cylinders upon start up. This can cause catastrophic damage to the connecting rods, pistons, and valve plates. To avoid this, BEFORE THE UNIT IS STARTED,

THE POWER SUPPLY SHOULD BE APPLIED TO THE UNIT FOR AT LEAST 12 HOURS, OR UNTIL THE BOTTOM OF THE COMPRESSOR IS WARM TO THE TOUCH. If the power has been

disconnected more than two hours, the power should be applied for six hours before restarting. Power should be applied to the unit continuously, except for service purposes. The crankcase heater should be checked for proper operation on a regular basis.

C. The OPERATIONS segment of this manual is divided into the

following sections:

3.2 Start up/operations - follow this segment to start the unit after the initial install to the process system or to restart the unit after reinstallation to the same or different process system. 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. This section includes information on 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 shut down, electrical power supply precautions, and disconnection from system.

3.2 START UP/OPERATION PROCEDURE

A. SYSTEM FILL

1. The VL series portable chiller has an internal reservoir which

must be filled and maintained for proper operation. All VL series chillers have a level switch mounted at the proper water level in the reservoir.

UGH021/0301 VL Series Portable Chillers, 2 to 40 Tons

Page: 19

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. FOR AUTOMATIC FILL (IF EQUIPPED): engage the

water supply to unit. The level switch will activate the make-up solenoid (figure

3.2A), which will open and the water supply will fill the reservoir tank. During operations, with the water supply source “on”, the unit will automatically maintain the correct reservoir level.

4. MANUAL FILL: disconnect the electrical power supply and remove all necessary cover panels to access the reservoir tank. Add fluid directly to the reservoir tank. When the pump is first started, as process lines are filled and air is purged, additional fluid may be required to restore the reservoir to the correct level.

B. ELECTRIC MOTOR PHASING (PUMP ROTATION)

1. The operator must determine the unit is phased correctly.

This is done by visually inspecting the rotation of the pump motor shaft and is outlined below. Incorrect phasing results in poor operation and eventual damage to the unit.

a. Supply electrical power to the unit by engaging the

unit’s disconnect switch. Once the correct voltage is supplied to the unit, the POWER light on the unit’s instrument display will illuminate.

b. Remove the necessary covers panel to access the

pump motor. Note that electrical power is

engaged at this point and caution must be observed while the electrical supply is engaged and cover panels are removed.

c. Locate the electric motor (figure 3.2B) The operator

must identify the motor shaft inside the electric motor housing. The motor shaft can be seen through the vent slots in the motor housing or by removing the shaft cover (figure 3.2C).

Figure 3.2ATypical make-up solenoid valve

Page: 20

VL Series Portable Chillers, 2 to 40 Tons UGH021/0301

d. Toggle the CHILLER

ON switch. This will quickly cycle the electrical motor “on” and then “off”.

e. Observe the motor

shaft. When the CHILLER ON switch is turned “on”, the motor shaft will rotate. When the CHILLER ON switch is turned “off”, the motor shaft will slowly “coast” to a stop. As the shaft slows to a stop, the operator must identify its rotation. Correct rotation (correct phase) is “clockwise”, when viewed from the rear of the motor. Incorrect rotation is “counterclockwise” (incorrect phase) when viewed from the rear of the motor. If the shaft does not rotate when the PUMP switch is toggled, the operator must identify the cause as outlined in this manual’s troubleshooting and repair section.

f. If the motor shaft is phased correctly (shaft turns in

a clockwise direction), continue with step C. If the motor shaft is NOT phased correctly (shaft turns in a counter-clockwise direction), continue the procedure with step 2.

2. If the motor shaft is NOT phased correctly, the operator must:

a. Disengage the electrical power supply to the unit at

the disconnect switch. Follow proper lockout procedures before proceeding. Verify the POWER light on the instrument display is off.

b. With the electrical power supply is disengaged,

reverse any two power leads of the power cord at the disconnect terminals.

c. Note: reversing any two power leads of the power

cord will correctly phase an incorrectly phased

Figure 3.2C

Motor shaft

Vent slots

Figure 3.2B

Electric motor

Pump

UGH021/0301 VL Series Portable Chillers, 2 to 40 Tons

Page: 21

power supply. The operator must reverse the

power leads at the disconnect switch only and NOT at the power entry terminals on the unit’s electrical panel. The unit’s internal electrical

system wiring is phased correctly at the factory and must not be altered in the field.

d. Visually inspect the rotation of the motor as

outlined step 1 to determine the unit is phased correctly.

C. PROCESS FLOW ADJUSTMENTS

1. The operator must determine and set proper water flow

rate for the most efficient and trouble free operation.

a. Water flow rate through the process is determined

by the pressure losses in the process loop. Generally, higher flow rates result in turbulent flow achieving maximum temperature control and lower maintenance. Since the evaporator in most liquid chillers is flow sensitive, the efficiency of operation is directly related to the flow of liquid.

b. Maximum chiller efficiency is obtained at

approximately 2.4 gpm per ton of rated capacity. Low liquid flow can reduce efficiency and in some cases allow ice to form in the evaporator which can damage the evaporator. Excessive flow will trip the motor overload protection circuit.

2. Activate the CHILLER ON rocker switch on the display to activate the process pump. Wait a few moments to allow air to be purge from system. Two items the operator must look for are low or excessive flow conditions.

3. LOW FLOW... to allow operation under a low flow condition, it is necessary to install a flow bypass system in the process circuitry. This will allow a portion of the flow to bypass the process and return directly to the chiller. This keeps the total flow above the cutoff point. Figure 3.2D illustrates a typical bypass loop.

Figure 3.2D Typical low flow by-pass loop

21 GPM 5 GPM

BYPASS

CHILLER PROCESS

THROTTLING VALVE 16 GPM

5 GPM21 GPM

Page: 22

VL Series Portable Chillers, 2 to 40 Tons UGH021/0301

4. EXCESSIVE FLOW... excessive flow can overload the process pump motor and cause eventual failure. This is a result of the process loop’s ability to flow water at a great rate than can be provided by the process pump. This eventually results in tripping the thermal motor overload relay (overload relays open) and the unit will shut down.

a. If an excessive flow situation is encountered and

the motor overload circuit has tripped, the operator must manually reset the overload relay (figure 3.2E) before operations can continue. This is done by opening the electrical panel cover, identifying the reset lever on the overload relay, and pushing the reset lever “in” until the overloads are reset (evidenced by a “clicking” sound as the overloads reset).

5. To overcome an excessive flow condition, the operator should set the process flow rate according to the motor amperage:

a. Remove electrical cover panel. Note that the

electrical power is engaged at this point and caution must be observed while the cabinet panel is open.

b. Identify the motor

starter block. This block consists of the motor starter contactor and the overload relay.

c. Place an amp

meter on a single power lead emanating from the overload relay.

d. Locate the electric pump motor. Identify

the motor name plate on the motor housing (figure

3.2F). The full load amp rating for the motor is listed on the name plate.

e. Engage the electrical power supply and start the

motor by switching ‘on’ the CHILLER ON rocker switch.

Figure 3.2E

Reset level on overload relay

Motor name plate

Figure 3.2F

UGH021/0301 VL Series Portable Chillers, 2 to 40 Tons

Page: 23

f. The amp meter will display the motor amps.

Compare the actual motor amps as displayed on the amp meter to the full load amp rating as listed on the motor name plate.

g. If the amp draw is excessive (higher than the listed

name plate amp rating), a throttling valve must be installed in the “from process” circuit line. The preferred throttling valve is a ball valve.

h. With the throttling valve installed, fully close the

valve and then engage the pump. Slowly open the throttling valve and monitor the motor amps as displayed on the amp meter until the actual motor amps equals the listed full load amp rating of the motor.

3.3 INSTRUMENT OPERATION

A. INSTRUMENT START-UP

1. When the correct electrical power and adequate water

supply pressure are supplied to the unit, it is possible to start the unit for temperature control duty.

2. When the electrical power supply is engaged to the unit, the instrument (figure 3.3A) will momentarily illuminate all indicating lights and digits on the display head. After a short delay, the instrument will display the software version number. At this time, the operator can verify that all lights and digits are functioning properly. If the operator

VL Chiller Control

Power

Pump

Compressor

Hot Gas Bypass

Temperature

To Process

Setpoint

Off

Page: 24

VL Series Portable Chillers, 2 to 40 Tons UGH021/0301

determines an indicating light or digit does not illuminate, the instrument must be removed and sent to the factory for repair. When power is supplied to the unit, the POWER light will illuminated.

3. Toggle ‘on’ the CHILLER ON rocker switch to activate the chiller. The operator can stop process operations (refrigerant and coolant circuits) by switching ‘off’ the CHILLER ON switch.

4. To select the operating setpoint, use the SELECT key to index through the TO PROCESS and SET POINT temperature functions until the SET POINT light is illuminated.

5. When the SET POINT light is illuminated, the setpoint temperature is shown in the temperature display window. Use the UP and DOWN ARROW keys to change the setpoint temperature.

6. PRECAUTIONS: the instrument is programmed from the factory with a setpoint range of 48° to 70°F. To operate below 48°F, the addition of inhibited propylene glycol and modification of the safety control settings are required. Diligent monitoring of the water/glycol solution is mandatory to prevent freezing of the evaporator. Freezing may cause the evaporator to rupture allowing water and freon to mix which will cause major damage to the refrigeration system. Operating above 70°F requires the addition of a refrigerant crankcase pressure regulating (CPR) valve. The CPR valve is necessary to prevent overloading of the compressor which can cause premature failure. Contact your local refrigeration contractor or the factory for further information. The operating range of the instrument may be changed to 20°F - 90°F by adjustment of the CPU DIP switch. Refer to the technical section of this manual for more information. The instrument is set up from the factory to give an alarm light and a 115 volt alarm output if the temperature to process deviates more than 10° from the setpoint.

7. After selecting the setpoint temperature, the operator may leave the display in the SET POINT state. The display will automatically return to the TO PROCESS temperature state after twenty seconds of inactivity.

8. The operator can stop operations by switching ‘off’ the CHILLER ON rocker switch. This will disengage the refrigerant and coolant circuits.

UGH021/0301 VL Series Portable Chillers, 2 to 40 Tons

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B. INSTRUMENT OPERATION

1. When the CHILLER ON rocker switch is toggled on, the

instrument will begin temperature control operations and the ‘to process’ temperature will begin to drop.

2. When the ‘to process’ temperature drops 1° below the setpoint, the instrument will activate the capacity control system to match the cooling capacity to the present load, as indicated by the HOT GAS BYPASS light (figure 3.3A).

3. If the load is less than the minimum capacity of the chiller, the ‘to process’ temperature will continue to drop. At 3° below setpoint the compressor will stop and enter a three minute time delay period before restarting at 1° above setpoint. The time delay is to prevent short cycling damage to the compressor.

C. INSTRUMENT CONTROLS

1. CHILLER ON SWITCH: this rocker switch

engages/disengages electrical supply to the compressor and pump circuit.

2. SELECT: depress to index through the TO PROCESS and SET POINT temperatures.

3. UP ARROW: depress and hold this push button to increase the setpoint temperature. If this push button is pressed momentarily the setpoint value is incremented by one degree. If the push button is held down for more than one second, the setpoint will increase slowly at first and then faster after about two seconds.

4. DOWN ARROW: depress and hold this push button to decrease the setpoint temperature. If this push button is pressed momentarily the setpoint value is incremented by one degree. If the push button is held down for more than one second, the setpoint will increase slowly at first and then faster after about two seconds.

D. INSTRUMENT STATUS DISPLAY

1. POWER: illuminates when the proper supply of electrical

power is applied to the unit.

2. PUMP: illuminates when the CHILLER ON rocker switch is turned on and the pump is operating. Even with the CHILLER ON rocker switch on, the PUMP light will not illuminate if a safety fault condition exists.

3. COMPRESSOR: illuminates when the instrument engages

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VL Series Portable Chillers, 2 to 40 Tons UGH021/0301

the compressor contactor. Engaging the compressor contactor supplies electrical current to the compressor. This action will decrease process water temperature.

4. CAPACITY CONTROL: illuminates when the instrument has engaged the capacity control system.

E. TEMPERATURE DISPLAY

1. A three digit display window indicates the appropriate

temperature in Fahrenheit. The window also displays the numeric value for the setpoint temperature. A red light will illuminate beside the parameter currently being displayed.

a. TO PROCESS: indicates liquid temperature being

delivered from the chiller.

b. SETPOINT: indicates selected temperature control

point.

3.4 SHUT DOWN/DISCONNECT SEQUENCE

A. PRECAUTIONS/WARNINGS

1. The operator must precisely follow all shut down

procedures outlined in this manual. If the operator fails to follow precisely all procedures outlined in this manual, an unsafe condition can develop resulting in damage to the unit or personal injury.

B. UNIT SHUT DOWN

1. To shut down the unit: toggle off the CHILLER ON rocker

switch. Maintain electrical power to the unit at all times except for service purposes. If the unit is to be disconnected from the process, disengage the voltage supply before removing power cord and process lines.

UGH021/0301 VL Series Portable Chillers, 2 to 40 Tons

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4.0 TROUBLESHOOTING

4.1 SENSORS

4.2 PROCESS PUMP

4.3 COMPRESSOR

4.4 BLOWER/FAN

4.5 LOW FLOW

4.6 HIGH PRESSURE

4.7 LOW PRESSURE

4.8 FREEZESTAT

4.9 OIL PRESSURE

4.10 CRANKCASE HEATER

4.11 ELECTRONICS

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VL Series Portable Chillers, 2 to 40 Tons UGH021/0301

4.1 SENSORS

A. The sensor is a solid state temperature transducer which converts

temperature input to proportional current output.

B. To quickly test for a defective probe, switch connections between

the defective probe and a probe known to be working properly.

4.2 PROCESS PUMP

A. The centrifugal pump is designed to operate at a specific flow and

pressure at the maximum run load amp draw of the motor. Too much flow can overload the motor and cause the overload circuit to open and stop the pump.

B. If the overload trips, check for electrical shorts, loose wires, or

blown fuses. If these check OK, reset the overload circuit and restart the chiller.

C. Check the amperage and if excessive, partially close the ‘from

process’ valve until the amperage is reduced to the proper level.

4.3 COMPRESSOR

A. Semi-hermetic compressors are protected by an external overload

device (Klixon switch, solid state module, etc.). If the safety switch opens, this indicates an overload condition exists.

B. Check for electrical shorts, loose wires, bad fuses, or bad motor

starter contacts. If these check ok, check for a defective protection device.

C. Hermetic compressors have internal protection.

4.4 BLOWER/FAN

A. Check for an electrical short, loose wires, bad fuses, or bad motor

starter contacts.

B. Check the blower for defective bearings or other forms of drag on

the blower wheel.

4.5 LOW FLOW

A. One pump chillers require 100% of the process flow to circulate

through the evaporator.

B. In some process conditions the minimum flow required cannot be

maintained making it necessary to install a bypass line between the to and from process lines.

UGH021/0301 VL Series Portable Chillers, 2 to 40 Tons

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4.6 HIGH PRESSURE

A. If the refrigerant high pressure safety switch has opened, this switch

must be manually reset after the problem has been resolved.

B. Refrigerant high pressure will vary with ambient temperature from a

minimum of 190 psi to as high as 280 psi. Check for restricted filters, broken or loose blower drive belts, restricted air flow.

C. On air-cooled models: maintain at least four feet of clearance for

each condenser intake.

D. On air-cooled models: check if the discharge duct work (if installed)

is undersized and restricting air flow.

4.7 LOW PRESSURE

A. If the refrigerant low pressure safety switch has opened, the cause

of the problem must isolated and resolved.

B. The switch will automatically reset when the pressure rises above

the cut-in pressure. If this does not occur contact the Conair service department for instructions.

C. The low pressure switch is set to cut-out at 58 psi and cut-in at 63

psi. If a low pressure condition exists for more than five seconds the compressor will stop and a “L-P” fault will appear in the display window.

D. After the refrigerant pressure rises above the cut-in pressure, a three

minute time delay will occur before the compressor restarts. This will protect the evaporator and compressor from damage should a problem occur in the refrigeration system or if the chiller is operated under circumstances which could cause damage to the refrigeration system.

E. If a low pressure fault occurs, check for blockage in the evaporator

water inlet. If a blockage is found, back flush the evaporator and flush complete process water system.

F. Check for low freon. The refrigerant sight glass should appear clear

when the unit is operating at 100% cooling capacity. Constant foam or bubbles indicate a loss of freon.

G. Check to see if the condensing media is too cold. On air condensed

units, the ambient air at the condenser intake must be at least 60°F. If this is not possible, a damper control assembly package may be required.

4.8 FREEZESTAT

A. The freezestat sensor bulb is located at the evaporator water outlet

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VL Series Portable Chillers, 2 to 40 Tons UGH021/0301

port. If the water out temperature of the evaporator reaches the freezestat setting the switch will open and stop the refrigeration compressor.

B. Check for restricted water flow and add a bypass line if necessary.

C. The setpoint is adjusted too low for the safety switch settings.

D. The freezestat is adjusted incorrectly or is defective.

4.9 OIL PRESSURE (Semi-hermetic Compressors)

A. This switch must be manually reset after the problem is resolved.

B. Check for low oil level in the compressor crankcase or insufficient

compressor warm up before start-up.

C. Defective crankcase heater, internal compressor damage causing

the compressor to pump too much oil through the system, defective oil pump, or plugged pick up screen in compressor oil sump. Note: only semi-hermetic compressors 15-30 tons have an oil pressure safety switch.

4.10 CRANKCASE HEATER (Semi-hermetic Compressors)

A. If the crankcase heater is not drawing current during the

compressor off cycle, check for a defective crankcase heater, defective fuses or defective interlock on the compressor starter.

4.11 ELECTRONICS

A. The Display/CPU is used for all normal set ups, diagnostics,

temperature readout and operational information. This is not normally a field repairable part. It is designed to be easily removed and replaced if a problem arises.

UGH021/0301 VL Series Portable Chillers, 2 to 40 Tons

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5.0 MAINTENANCE

5.1 WARRANTY SERVICE PROCEDURE

5.2 PERIODIC PREVENTATIVE MAINTENANCE

5.3 SPECIAL MAINTENANCE

5.4 SOLENOID VALVE SERVICE

5.5 PUMP SEAL SERVICE

5.6 CHECKING THE REFRIGERANT CHARGE

5.7 PROPER CLEANING PROCEDURE FOR BRAZED PLATE EVAPORATOR

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VL Series Portable Chillers, 2 to 40 Tons UGH021/0301

5.1 WARRANTY SERVICE PROCEDURE

A. In the event of a problem with a chiller that can not be resolved by

normal troubleshooting procedures, the customer is invited to consult the Conair service department for assistance. The correct model number and serial number of the chiller must be available. The service department will attempt to isolate the problem and advise repair procedures. Often times, with the customer’s input and with the machine diagnostics, problems can be determined with “over-the-phone” consultation.

B. If the problem is beyond the scope of “over-the-phone”

consultation, and if the warranty status of the machine is valid, Conair will contact the nearest authorized service contractor and provide authorization to conduct an “on-site” inspection of the unit in order to determine the course of repair. If the chiller is not covered by the warranty, Conair will advise on the repair and recommend available service contractors.

C. Conair manufactures a complete line of heat transfer equipment. It

is of the utmost importance that Conair have the correct model number and serial number of the machine in question. This will allow Conair to obtain the correct manufacturing records which will help the service department to properly troubleshoot the problem and obtain the proper replacement parts when they are required. This information is stamped on the metal data tag that is attached to the machine.

D. The Conair service department must be notified prior to any repair

or service of a warranty nature. Warranty claims will not be honored without prior authorization.

5.2 PERIODIC PREVENTATIVE MAINTENANCE

A. Lubricate all motors. Note that some motors are supplied with

sealed bearings.

B. Tighten all wire terminals.

C. Clean and check motor starter and contactor contacts.

D. Check safety switch settings.

E. Clean condenser fins of dust and dirt.

F. Back flush evaporator.

G. Check glycol/water solution ratio for operating temperature.

H. Check system for leaks.

UGH021/0301 VL Series Portable Chillers, 2 to 40 Tons

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I. Refrigerant sight glass: check for bubbles when compressor is

operating at 100%. Check the moisture indicator for a color other than green.

J. Clean unit.

5.3 SPECIAL MAINTENANCE

A. Any service of the refrigeration system must be accomplished by a

certified refrigeration technician.

1. Vacuum check compressor.

2. Addition of compressor oil.

3. Addition of refrigerant.

4. Repair of a refrigerant leak.

5. Adjustment of super heat.

6. Changing of filter-drier or drier core.

7. Repair of a refrigeration solenoid.

8. Valve plate replacement on compressor. (Semi-hermetic

compressors only)

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VL Series Portable Chillers, 2 to 40 Tons UGH021/0301

5.4 SOLENOID VALVE SERVICE

A. VLA units with the water make-up

system use a solenoid valve (figure

5.4A) to regulate the level in the

reservoir tank. The solenoid valve is controlled by the float switch.

B. Generally, solenoid valves fail due

to poor water quality, low water flow, or defective valve elements.

C. The operator should follow this

procedure to service the make-up solenoid valve:

1. Disengage process operations according to the procedure outlined in section 3.4. The operator must be certain process fluid temperature is under 100°F and pressure is relieved (pressure gauge reads “0”) and water system flow is shut off and all pressure relieved.

2. Disengage main power supply. The operator must verify the POWER light on the display is “off”.

3. Remove or open any access cover panel and set aside to gain access to the solenoid valve.

4. The operator must be certain all water supply system pressure is relieved.

5. Identify the retaining screw (figure 5.4B) on the solenoid valve coil. Remove the screw. Keeping all electrical connections intact, lift the coil off of the enclosure tube and set aside.

6. Use a pair of channel lock pliers or a pipe wrench to separate the bonnet assembly from the valve body. The plunger is “loose” inside the enclosing tube. Be certain it is retained in the enclosure tube as the bonnet is removed (figure 5.4C).

7. Identify the diaphragm assembly. Gently remove the assembly from the valve body (figure 5.4D).

8. Identify the mesh screen. Gently removed the mesh

Coil

Figure 5.4B

Retaining screw

Typical water make-up solenoid valve

Figure 5.4A

UGH021/0301 VL Series Portable Chillers, 2 to 40 Tons

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screen and clean or replace as necessary.

9. Clean the valve body.

10. Reset the mesh screen into

the valve body.

11. If a new diaphragm assembly was obtained, continue with step 12. If not, disassemble the diaphragm assembly and note component order (figure 5.4E). Clean the valve port, plate, collar and O-ring. Once cleaned, reassemble the diaphragm.

12. Set the reassembled diaphragm assembly or the new assembly back into the valve body. The stem should be facing out of the valve body.

13. Inset the plunger with spring first into the enclosing tube of the top bonnet (figure 5.4F). Holding the plunger in the enclosure tube, set the top bonnet onto the valve body and tighten.

14. Place the coil onto the top bonnet and replace the retaining screw.

15. Open the water supply to circulate water to the make-up system. Check the solenoid valve for leakage. Restart the unit as outlined in section 3.

Figure 5.4F

Plunger

Spring

Top bonnet

Enclosure tube

Top bonnet

Figure 5.4C

Enclosure tube

Plunger

Diaphragm assembly

Figure 5.4D

O-Ring

Diaphragm assembly

Mesh screen

Figure 5.4E

O-Ring

Diaphragm and stem

Collar

Plate

5.5 PUMP SEAL SERVICE

A. The VLA unit pump seal is a carbon/niresist shaft seal assembly

including a stationary member, rotating member and tension spring (figure 5.5A).

B. The operator can

determine the pump seal is leaking when fluid is identified leaking from the pump case adapter. Generally, a pump seal will leak due to inadequate unit pressure, excessive flow and poor fluid quality.

C. The operator should

follow this procedure to replace the pump seal:

1. Disengage process operations according to the procedure outlined in section 3.4. The operator must be certain process fluid temperature is under 100°F and water make-up flow is shut off and all pressure relieved.

2. Disengage main power supply. The operator must verify the POWER light on the display is “off”.

3. Access the pump motor by opening or removing any cover panels as necessary (figure 5.5B).

4. Drain machine. Drain fluid into a suitable container for reuse or disposal according to manufacturer’s instructions (if a glycol solution is used).

5. Locate and remove the three motor wire leads from the motor wiring terminals. The operator should “map” the wire terminal locations to ensure correct rewiring. The power cord should be removed from the motor housing (figure 5.5C).

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VL Series Portable Chillers, 2 to 40 Tons UGH021/0301

Stationary member

Rotating Member

Tension Spring

Figure 5.5A

Pump motor

Figure 5.5B

Pump motor power cord

Figure 5.5C

6. Locate and remove the pump casing bolts. These bolts secure the motor and motor adapter to the pump casing (figure 5.5D).

7. Separate the motor and motor adapter from the pump casing to expose the pump impeller (figure

5.5E). Remove the motor and motor adapter from the unit and place on a workbench to continue the procedure.

8. Locate and remove the dust cap from motor end to expose slotted motor shaft. The motor shaft is free to rotate, but must be secured to remove the impeller. To secure the motor shaft, insert a flat bladed screw driver in slot to hold the shaft stationary (Figure 5.5F).

9. Locate and remove the impeller locking screw (Figure 5.5G). Using a socket and ratchet, the impeller retaining screw can be removed. Once the retaining screw is removed, the impeller can be “unthreaded” from the motor shaft to expose the pump seal assembly.

10. Remove all seal parts (Figure 5.5H). Note seal component arrangement to facilitate reassembly.

11. Clean motor shaft and lubricate with a mild soap solution.

12. Install new stationary seal member in the pump casing cavity (figure 5.5I).

UGH021/0301 VL Series Portable Chillers, 2 to 40 Tons

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Typical pump casing bolts

Figure 5.5D

Motor shaft

Figure 5.5F

Typical impeller

Figure 5.5G

Impeller

Figure 5.5E

The operator must be certain the stationary seal member is fully squared and seated in cavity.

13. Slide the rotating member onto the lubricated pump shaft (figure 5.5J). The operator must be certain not to damage or tear rubber bellows assembly.

14. Place the spring onto the rotating member.

15. Align the impeller, spring and rotating member before reinstalling the impeller (figure 5.5K). The operator must be certain the spring and rotating member are aligned before the impeller is fully tighten and the impeller retaining screw is reinstalled.

16. Clean pump casing, cavities, impeller and Oring before reassembly.

17. Mate the motor and motor adapter to the pump casing. Reinstall the pump casing bolts.

18. Reconnect the motor power cord and leads.

19. Restore all cover panels as were removed.

E. When the pump seal replacement

procedure is complete, the operator should check for leaks before restarting the unit according the section 3.

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VL Series Portable Chillers, 2 to 40 Tons UGH021/0301

Stationary member

Figure 5.5I

Rotating member

Figure 5.5J

Seal members

Figure 5.5K

Seal components

Figure 5.5H

UGH021/0301 VL Series Portable Chillers, 2 to 40 Tons

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5.6 CHECKING THE REFRIGERANT CHARGE

A. All standard Conair chillers are manufactured with thermostatic

expansion valves as the metering device to the evaporator.

B. All Conair chillers have a refrigerant sight glass with a moisture

indicator. To check the refrigerant charge under normal operating conditions:

1. Remove the plastic cap covering the sight glass, if installed.

2. Start the chiller and allow system pressures and

temperatures to stabilize.

3. With the unit operating at 100% capacity (not in the “hot gas bypass” mode) the sight glass should appear clear with no foam or bubbles evident. If foam or bubbles are evident, the chiller has suffered from a loss of refrigerant and should be checked by a qualified refrigeration technician.

4. The “dot” in the middle of the sight glass is the moisture indicator. It should appear green at all times. A white or yellow color indicates moisture has invaded the refrigeration system, which is detrimental to the life of the compressor. The filter-drier should be replaced by a qualified refrigeration technician.

Figure 5.6A

Typical refrigerant sight glass (cap removed)

Moisture Indicator

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VL Series Portable Chillers, 2 to 40 Tons UGH021/0301

5.7 PROPER CLEANING PROCEDURE FOR BRAZED PLATE EVAPORATORS

A. The brazed plate evaporator is

made of stamped stainless steel plates, furnace brazed together with copper based joints. The complex geometry of the flow passages promotes turbulent flow which gives high efficiency and reduces fouling by mineral deposits. Large solids such as plastic pellets or chunks of mineral deposits will collect at the water inlet port at the evaporator and restrict flow through some of the passages. If this possibility exists, Conair recommends filters or strainers be added to the “from process” line. If the evaporator becomes fouled there are a couple of methods for cleaning.

B. To begin, remove the piping to the “water in” port at the

evaporator. Remove any solids that have collected at this point. Then backflush the evaporator to remove any solids that may be trapped between the plates (see backflush procedure next page). If there are mineral deposits adhered to the plates, the evaporator must be backflushed with a mild acid solution (5% phosphoric or 5% oxalic acid is recommended.) After cleaning rinse with clear water before returning to service. Continue with step C on next page.

Typical evaporator installation

Figure 5.7A

RAZED PLATE HEAT EXCHANGER

(EVAPORATOR)

FREON OUT

FREON IN

ORIGINAL WATER IN PORT

BACKFLUSH WATER OUT PORT

(ROUTE WATER TO PROPER

SEWER OR DRAIN CONTAINER)

ORIGINAL WATER OUT PORT

BACKFLUSH WATER IN PORT

(SUPPLY BACKFLUSHING WATER

FLOW TO THIS PORT)

UGH021/0301 VL Series Portable Chillers, 2 to 40 Tons

Page: 41

C. Backflushing procedure:

1. Turn off all power to the machine. For chillers with a

reservoir tank, drain the tank to below the evaporator outlet. For chillers without a reservoir tank, drain total unit.

2. Connect a water supply hose to the evaporator water outlet. If acid cleaning, connect the discharge hose from the acid pump to the evaporator outlet port.

3. Connect a hose to the evaporator water supply port and to an appropriate containment vessel. If acid cleaning, connect the evaporator water inlet port to an acid solution reservoir tank. Dispose of all backflush fluid according to local codes.

4. The cleaning fluid source should have at least 20 psi available. If acid cleaning, follow the instructions supplied with the acid solution carefully.

5. When the procedure is complete, reinstall all water lines to original factory orientation. Restart the unit and check for proper operation.

6. Note: this procedure is not normal maintenance. Maintaining proper water quality and filtration will minimize the need to backflush the evaporator.

VL Series Portable Chillers, 2 to 40 Tons UGH021/0301

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UGH021/0301 VL Series Portable Chillers, 2 to 40 Tons

Page: 43

6.0 COMPONENTS

6.1 WATER SYSTEM

6.2 REFRIGERATION SYSTEM

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VL Series Portable Chillers, 2 to 40 Tons UGH021/0301

6.1 WATER SYSTEM

A. MOTOR/PUMP ASSEMBLY: the

motor/pump assembly circulates chilled fluid to the process loop. The pump assembly is built of total stainless steel to maintain water quality (figure 6.1A).

B. FREEZESTAT: the freezestat aids in

protecting the evaporator from potential freezing. The freezestat is factory adjusted to 40°F. The freezestat must be field adjusted for operating with setpoints below 48°F (figure 6.1B).

6.2 REFRIGERATION SYSTEM

A. COMPRESSOR: hermetic or semi-

hermetic compressors take low pressure/low temperature refrigerant gas and compress the gas into high pressure/high temperature gas (figure 6.2A).

B1. WATER COOLED CONDENSER:

the water cooled condenser removes BTU’s (heat) from the compressed refrigerant gas. As the heat is removed, the gas “condenses” into a liquid state, still under high pressure. Tube-in-shell condensers are used on 15-30 ton models. Tube-in-tube condensers are used on 5-10 ton models. Water regulator valves are used on all models to control the refrigerant head pressure by modulating the condenser water flow (figure

6.2B1).

B2. AIR COOLED CONDENSER: the air

cooled condenser removes BTU’s 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 via a motor driven fan assembly or centrifugal blower (figure 6.2B2).

Mechanical freezestat

Figure 6.1B

Hermetic compressor

Semi-hermetic compressor

Figure 6.2A

Pump

Figure 6.1A

Tube/shell condenser

Regulator valve

Tube/Tube condenser

Figure 6.2B1

UGH021/0301 VL Series Portable Chillers, 2 to 40 Tons

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C. FILTER-DRIER: the filter-drier

removes contaminants and moisture from the liquid refrigerant (figure

6.2C).

D. LIQUID LINE SOLENOID VALVE:

controlled by the instrument, this valve closes when the compressor cycles off to prevent refrigerant liquid from migrating to the evaporator. The valve opens when the compressor cycles on (figure 6.2D).

E. 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 element. Element color is normally green. If the color of the element is chartreuse or yellow, the system has been contaminated with moisture. In such case, the filter-drier must be replaced. The replacement of the filter-drier must be completed by a qualified refrigerant service technician (figure 6.2E).

E. EXPANSION VALVE: the expansion

valve throttles flow of refrigerant liquid into the evaporator and creates a pressure drop in the refrigerant system that allows the liquid refrigerant to “boil off” inside the evaporator (figure 6.2F).

F. EVAPORATOR: the evaporator is a

brazed plate heat exchanger where the refrigerant liquid is allowed to evaporate (boil off) to absorb heat (BTU) from the process fluid. As the heat is absorbed, the process fluid is chilled (figure 6.2G).

G. HOT GAS BY-PASS SOLENOID: the

hot gas by-pass solenoid prevents short cycling of the compressor by reducing the capacity by 50% when the process fluid temperature nears the setpoint (figure 6.2H).

Typical filter-drier

Figure 6.2C

Typical liquid line solenoid valve

Figure 6.2D

Typical refrigerant sight glass

Figure 6.2E

Fans

Blower

Figure 6.2B2

H. HIGH/LOW PRESSURESTATS: the

high/low pressurestats protect the refrigeration system from unsafe operating levels. The high pressure switch is factory set to open at 325 psi and protects the refrigeration components and personnel from potential damage of injury from excessive 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 58 psi and to close at 63 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 48°F (figure 6.2I).

I. Liquid receiver: located after the

condenser, this component receives and stores liquid refrigerant leaving the condenser.

J. Service valves: have been provided

throughout the system. Only a qualified refrigeration service technician shall operate these valves.

K. Crankcase heater: insures that

freon and compressor crankcase oil do not mix during the compressor’s ‘off ’ cycles. (Semi-hermetic only)

L. Oil pressure safety switch:

protects the compressor from lubrication failure. (Semi-hermetic only)

Typical evaporator

Figure 6.2G

Typical hot gas bypass valve

Figure 6.2H

High pressurestat

Low pressurestat

Figure 6.2I

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VL Series Portable Chillers, 2 to 40 Tons UGH021/0301

Typical expansion valve

Figure 6.2F

UGH021/0301 VL Series Portable Chillers, 2 to 40 Tons

Page: 47

7.0 RELATED DRAWINGS

7.1 VLA-5/7.5/10 MECHANICAL SCHEMATIC

7.2 VLA-15/20/25/30 MECHANICAL SCHEMATIC

7.3 VLA-5A PHYSICAL

7.4 VLA-7.5/10 PHYSICAL

7.5 VLA-15/20/25/30 PHYSICAL

7.6 DUCT SCHEMATIC FOR AIR COOLED CHILLERS

7.7 VLA-5A/7.5/10 ELECTRICAL

7.8 VLA-15/20/25/30 ELECTRICAL

7.9 VLW-5/7.5/10 MECHANICAL SCHEMATIC

7.10 VLW-15/20/25/30 MECHANICAL SCHEMATIC

7.11 VLW-5/7.5/10 PHYSICAL

7.12 VLW-15/20/25/30/40 PHYSICAL

7.13 VLW-5/7.5/10 ELECTRICAL

7.14 VLW-15/20/25/30 ELECTRICAL

Page: 48

VL Series Portable Chillers, 2 to 40 Tons UGH021/0301

7.1 VLA-5/7.5/10 MECHANICAL SCHEMATIC

FROM PROCESS

PORT CONNECTION

LEVEL SWITCH (optional)

SERVICE LID

(optional)

MAKE-UP PORT

CONNECTION

(optional)

MAKE-UP

SOLENOID VALVE

TO PROCESS

PORT CONNECTION

TO PROCESS

SENSOR PROBE

(5-ton model uses single fan)

AIR-COOLED CONDENSER w/FANS

LOW PRESSURE

SAFETY SWITCH

EVAPORATOR

RESERVOIR TANK

HOT GAS

BYPASS VALVE

RECEIVER

LIQUID LINE

COOLANT PUMP

EXPANSION VALVE

SIGHT GLASS

REFRIGERANT

LIQUID LINE

SOLENOID VALVE

FILTER-DRIER

COMPRESSOR

HIGH PRESSURE SAFETY SWITCH

(may be Scroll Hermetic or Recip)

UGH021/0301 VL Series Portable Chillers, 2 to 40 Tons

Page: 49

7.2 VLA-15/20/25/30 MECHANICAL SCHEMATIC

FROM PROCESS

PORT CONNECTION

LEVEL SWITCH (optional)

(optional)

MAKE-UP

SOLENOID VALVE

SERVICE LID

(optional)

MAKE-UP PORT

CONNECTION

TO PROCESS

PORT CONNECTION

TO PROCESS

SENSOR PROBE

LOW PRESSURE

AIR-COOLED CONDENSER w/blower

SAFETY SWITCH

EVAPORATOR

RESERVOIR TANK

HOT GAS

BYPASS VALVE

RECEIVER

LIQUID LINE

COOLANT PUMP

EXPANSION VALVE

SIGHT GLASS

REFRIGERANT

LIQUID LINE

SOLENOID VALVE

FILTER-DRIER

COMPRESSOR

HIGH PRESSURE SAFETY SWITCH

(may be Scroll Hermetic or Recip)

Page: 50

VL Series Portable Chillers, 2 to 40 Tons UGH021/0301

7.3 VLA-5 PHYSICAL

51"

PUM

COMPRESSOR

HOT GAS BYPASS

WER

TEMPERATURE

TO PROCESS

SETPOINT

S E L

E C

I L

34"

38"

UGH021/0301 VL Series Portable Chillers, 2 to 40 Tons

Page: 51

7.4 VLA-7.5/10 PHYSICAL

51"

POWER

PUMP

COMPRESSOR

TEMPERATURE

HOT GAS BYPASS

TO PROCESS

SETPOINT

S E L

E C

I L

L E

54"

34"

Page: 52

VL Series Portable Chillers, 2 to 40 Tons UGH021/0301

7.5 VLA-15/20/25/30 PHYSICAL

94"

O W

U M

O M

O T

58"

E R

E S

S O

S S

T O

R O

E S

S S E

T P

I N

S E

L E C

67 1/2"

UGH021/0301 VL Series Portable Chillers, 2 to 40 Tons

Page: 53

7.6 DUCT SCHEMATIC FOR AIR COOLED CHILLERS

NOTE: THIS DRAWING IS FOR EXPLANATION PURPOSES ONLY, NOT FOR CONSTRUCTION PURPOSES

Description

Item

Weather cap

Screen

Flashing to suit

Roof curb

Plant roof

Butterfly with counterbalance

Separate duct support from roof

Gate control for exhaust air flow

Manual chain control

Duct to plant heating system

Mating collar

Chiller air exhaust port

Air cooled chiller

Page: 54

VL Series Portable Chillers, 2 to 40 Tons UGH021/0301

7.7 VLA-5/7.5/10 ELECTRICAL

This electrical drawing is presented for illustration purposes only. For exact details, consult the electrical drawing supplied with your machine.

110VAC SEC.

TRANSFORMER

HEATER

CRANKCASE

FAN MOTOR #2

REQUIRED ON 7.5 & 10 TON

FAN MOTOR

COMPRESSOR

19 19

GROUND

POWER ENTRY

FU 1 FU 2

ANTI-DRAIN BACK SOLENOID

(OPTIONAL)

MOTOR COIL

22 50

22 22

1 MOL

21 22

OPTIONAL CUST. SUPPLIED CONTACTS

FOR REMOTE START/STOP.

HOT GAS BY-PASS SOLENOID

LIQUID LINE SOLENOID

5025

262626

HIGH PRESSURESTAT

COMPRESSOR COIL

FREEZESTAT

INSTRUMENT GROUND

1 MOL

PROCESS PUMP

RED

BRN

LOW PRESSURESTAT

JUMPER

RED/YEL

GRN

RED/BRN

VL Chiller Control

RED/WHT

To Process

Setpoint

Temperature

Power

Pump

BLU

Compressor

Hot Gas Bypass

24 25

ORG

MOLEX

WHT

Off

PROBE

TO PROCESS

UGH021/0301 VL Series Portable Chillers, 2 to 40 Tons

Page: 55

7.8 VLA-15/20/25/30 ELECTRICAL

This electrical drawing is presented for illustration purposes only. For exact details, consult the electrical drawing supplied with your machine.

POWER ENTRY

L1L2L3

110VAC SEC.

GROUND

FU 1 FU 2

4 MOL

TRANSFORMER

HEATER

CRANKCASE

BLOWER

COMPRESSOR

WATER MAKE-UP SOLENOID (OPTIONAL)

5020

TANK FLOAT

19 20

23 2322

2 MOL

1 MOL

MOTOR COIL

OPTIONAL

(OPTIONAL)

ANTI DRAIN-BACK SOLENOID

23 50

INSTRUMENT GROUND

HOT GAS BY-PASS SOLENOID

LIQUID LINE SOLENOID

28 50

BLOWER COIL

COMPRESSOR COIL

OIL PRESSURE

SAFETY SWITCH

32A

COMPRESSOR

CONTROL MODULE

4 MOL

HIGH PRESSURESTAT

(OPTIONAL)

2 MOL

1 MOL

19 19

PROCESS PUMP EVAPORATOR PUMP

RED

RED/BLU

FOR REMOTE START/STOP.

OPTIONAL CUST. SUPPLIED CONTACTS

212423

JUMPER

RED/YEL

RED/BRN

GRN

RED/WHT

To Process

Setpoint

MOLEX

WHT

RED/ORG

BLU

Off

Temperature

Power

Pump

Compressor

Hot Gas Bypass

FREEZESTAT

ORG

RED/BLK 29

TO PROCESS

LOW PRESSURESTAT

BRN

PROBE

VL Chiller Control

Page: 56

VL Series Portable Chillers, 2 to 40 Tons UGH021/0301

7.9 VLW-5/7.5/10 TON MECHANICAL SCHEMATIC

CONNECTION

MAKE-UP PORT

MAKE-UP

(OPTIONAL)

SOLENOID VALVE

SERVICE LID

FROM PROCESS

PORT CONNECTION

LEVEL SWITCH (OPTIONAL)

TO PROCESS

PORT CONNECTION

TO PROCESS

SENSOR PROBE

PORT CONNECTION

CONDENSER WATER IN

WATER REGULATOR VALVE

WATER COOLED CONDENSER

PORT CONNECTION

CONDENSER WATER OUT

LOW PRESSURE SAFETY SWITCH

EVAPORATOR

RESERVOIR TANK

HOT GAS

BYPASS VALVE

COOLANT PUMP

EXPANSION VALVE

SIGHT GLASS

REFRIGERANT

FILTER-DRIER

COMPRESSOR

HIGH PRESSURE

SAFETY SWITCH

LIQUID LINE

SOLENOID VALVE

UGH021/0301 VL Series Portable Chillers, 2 to 40 Tons

Page: 57

7.10 VLW-15/20/25/30 TON MECHANICAL SCHEMATIC

PORT CONNECTION

CONDENSER WATER OUT

PORT CONNECTION

CONDENSER WATER IN

WATER REGULATOR VALVE

FROM PROCESS

SERVICE LID

PORT CONNECTION

LEVEL SWITCH (OPTIONAL)

MAKE-UP PORT

CONNECTION (OPTIONAL)

MAKE-UP

(OPTIONAL)

SOLENOID VALVE

EVAPORATOR

TO PROCESS

PORT CONNECTION

TO PROCESS

SENSOR PROBE

COOLANT PUMP

RESERVOIR TANK

LOW PRESSURE SAFETY SWITCH

FILTER-DRIER

WATER COOLED CONDENSER

COMPRESSOR

HIGH PRESSURE

SAFETY SWITCH

HOT GAS

BYPASS VALVE

LIQUID LINE

SOLENOID VALVE

EXPANSION VALVE

SIGHT GLASS

REFRIGERANT

Page: 58

VL Series Portable Chillers, 2 to 40 Tons UGH021/0301

7.11 VLW 5/7.5/10 TON PHYSICAL

34"

P O

W E

R P U

M P

C O

T O

P R

O C

E S

S S E

T P O

I N

S E

E C T

IL L

R O N

38"

32"

UGH021/0301 VL Series Portable Chillers, 2 to 40 Tons

Page: 59

7.12 VLW 15/20/25/30 TON PHYSICAL

P O

R P U

C O

E O

Y P

O P

O C

E S

E T

P O

I N

S E

L E

51"

L E

54"

34"

Page: 60

VL Series Portable Chillers, 2 to 40 Tons UGH021/0301

7.13 VLW 5/7.5/10 TON ELECTRICAL

110VAC SEC.

TRANSFORMER

HEATER

CRANKCASE

GROUND

FU 1 FU 2

MOTOR COIL

22 22

22 50

ANTI-DRAIN BACK SOLENOID

(OPTIONAL)

HOT GAS BY-PASS SOLENOID

LIQUID LINE SOLENOID

5025

262626

COMPRESSOR COIL

INSTRUMENT GROUND

1 MOL

21 22

POWER ENTRY

OPTIONAL CUST. SUPPLIED CONTACTS

FOR REMOTE START/STOP.

RED/BRN

GRN

RED/WHT

To Process

Temperature

LOW PRESSURESTAT

JUMPER

RED/YEL

1 MOL

COMPRESSOR

PROCESS PUMP

RED

BRN

HIGH PRESSURESTAT

FREEZESTAT

24 25

BLU

ORG

MOLEX

Off

Setpoint

WHT

TO PROCESS

PROBE

Power

Pump

VL Chiller Control

Compressor

Hot Gas Bypass

UGH021/0301 VL Series Portable Chillers, 2 to 40 Tons

Page: 61

7.14 VLW 15/20/25/30 TON ELECTRICAL

110VAC SEC.

GROUND

TRANSFORMER

HEATER

CRANKCASE

FU 1 FU 2

POWER ENTRY

MOTOR COIL

22 23

1 MOL

(OPTIONAL)

23 50

ANTI DRAIN-BACK SOLENOID

INSTRUMENT GROUND

HOT GAS BY-PASS SOLENOID

5027

LIQUID LINE SOLENOID

502626

OIL PRESSURE

SAFETY SWITCH

COMPRESSOR

CONTROL MODULE

COMPRESSOR COIL

5026

19 50

1 MOL

COMPRESSOR

PROCESS PUMP

RED

FOR REMOTE START/STOP.

OPTIONAL CUST. SUPPLIED CONTACTS

LOW PRESSURESTAT

BRW

212222

JUMPER

RED/YEL

RED/BRN

GRN

RED/WHT

To Process

Temperature

Setpoint

MOLEX

BLU

Off

4 MOL

FREEZESTAT

ORG

HIGH PRESSURESTAT

WHT

PROBE

TO PROCESS

Power

Pump

Compressor

VL Chiller Control

Hot Gas Bypass

VL Series Portable Chillers, 2 to 40 Tons UGH021/0301

Page: 62

THIS PAGE INTENTIONALLY BLANK

UGH021/0301 VL Series Portable Chillers, 2 to 40 Tons

Page: 63

8.0 APPENDIX

8.1A ‘VLW’ SPECIFICATIONS

8.1B ‘VLA’ SPECIFICATIONS

8.2 OPERATION BELOW 48°F

8.3 WATER QUALITY CONTROL

8.4 INHIBITED PROPYLENE GLYCOL

8.5 MAINTAINING PROPER WATER FLOW

8.6 LOW FLOW BYPASS CIRCUIT

8.7 CHILLER CAPACITY AND DERATE CHART

8.8 OVERHEAD PIPING KIT

8.9 PRESSURE - TEMPERATURE CHART FOR R-22 REFRIGERANT

8.10 ENGINEERING FORMULAS

8.11 SPARE PARTS LIST - WATER COOLED MODELS

8.12 SPARE PARTS LIST - AIR COOLED MODELS

Page: 64

VL Series Portable Chillers, 2 to 40 Tons UGH021/0301

8.1 SPECIFICATIONS

MODEL VLA-2 VLA-4 VLA-5 VLA-7.5 VLA-10 VLA-15 VLA-20 VLA-25 VLA-30 Performance characteristics

Capacity* ton 2 4 5 7.5 10 15 18 24 26 Compressor Hp {kW}

✝

2 {1.5} 4 {2.9} 5 {3.7} 7.5 {5.6} 10 {7.5} 15 {11} 2x10 {15} 2x13 {19} 2x15 {22} Pump Hp {kW} 0.75 {5.6} 0.75 {5.6} 2 {1.5} 2 {1.5} 2 {1.5} 3 {2.2} 3 {2.2} 5 {3.7} 5 {3.7} Process flow‡gpm {lpm} 4.8 {18} 8.4 {32} 12 {45} 18 {68} 24 {90} 36 {136} 48 {182} 60 {227} 72 {273} Process pressure§psi {bar} 40 {2.76} 38 {2.62} 63 {4.34} 58 {4.0} 57 {3.9} 45 {3.1} 41 {2.83} 59 {4.07} 57 {3.93} Reservoir capacity gal {liters} 15 {57} 25 {95} 25 {95} 25 {95} 25 {95} 65 {246} 65 {246} 65 {246} 65 {246} Condenser assembly type Fan Fan Fan Fan Fan Blower Blower Blower Blower Condenser fan power Hp {kW} 0.33 {0.25} 0.75 {5.6} 0.75 {5.6} 1.5 {1.1} 1.5 {1.1} 7.5 {5.6} 10 {7.5} 15 {11} 20 {15} Condenser air flow ft3/min 2,000 5,000 5,000 10,000 10,000 15,000 20,000 25,000 30,000

{liters/min} {56,634} {141,584} {141,584} {283,168} {283,168} {424,752} {566,337} {707,921} {849,505}

Condenser static pressure, in. H20 — — — — — 1.35 1.35 1.30 1.30 Dimensions in {mm}

Height 30 {762} 60 {1524} 60 {1524} 60 {1524} 60 {1524} 96 {2438} 96 {2438} 96 {2438} 96 {2438} Width 24 {610} 34 {864} 34 {864} 34 {864} 34 {864} 58 {1473} 58 {1473} 58 {1473} 58 {1473} Depth 37 {940} 40 {1016} 40 {1016} 56 {1422} 56 {1422} 70 {1778} 70 {1778} 70 {1778} 70 {1778}

Pipe size NPT in. Process (to and from) 0.75 1.0 1.25 1.25 1.25 1.5 1.5 2.0 2.0 Make-up (optional) 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 Weight lb {kg} Shipping 415 {188} 600 {272} 700 {318} 1250 {567} 1300 {590} 1790 {812} 2100 {953} 2300 {1043} 2300 {1043} Voltage running/full load amps** run full run full run full run full run full run full run full run full run full 230V/3 phase/60hz 15 15 25 25 26 30 36 45 42 45 78 90 88 100 122 138 148 168 460V/3 phase/60hz 7 7 12 12 13 15 18 23 21 26 39 45 44 50 61 69 74 84 575V/3 phase/60hz — — 10 10 11 12 15 19 17 21 32 36 36 40 49 56 60 68

Refrigerant HCFC-22

SPECIFICATION NOTES

Ton capacity at 12,000 BTU/ton @ 50°F LWT @ 115°F condensing temperature. Consult factory for other conditions. Capacity ratings are ±

5% based on compressor manufacturer’s ratings and are subject to change without notice. Capacity multipliers are: 50°F - 1.00; 40°F - 0.80; 30°F - 0.60; 20°F - 0.40.

✝

Hermetic scroll compressor.

‡

Based on 50°F (10°C) water temperature leaving the chiller and 60°F (16°C) water temperature returning to the chiller.

Pressure at pump discharge. Consult pump curve for exact characteristics.

** Standard voltage is 208-230V/3 phase/60Hz. All others are optional. No allowance for inrush. Service disconnect by owner. Full load amps

must be used to size disconnects and supply conductors.

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

VLA MODELS, 2 TO 30 TONS

UGH021/0301 VL Series Portable Chillers, 2 to 40 Tons

Page: 65

SPECIFICATION NOTES

* Ton capacity at 12,000

BTU/ton @ 50°F LWT @ 115°F condensing temperature. Capacities may be ± 5% as reserved by the compressor manufacturer. Capacity multipliers are: 50°F - 1.00; 40°F - 0.80; 30°F - 0.60; 20°F - 0.40.

✝

Consult pump curve for

exact characteristics.

‡

Flow (GPM) rate is

based on 60°F city water, 85°F tower water at 20 PSI with a clean condenser.

No allowance for inrush.

Service disconnect by owner. Full load amps must be used to size disconnects and supply conductors.

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

MODEL VLW-5 VLW-7.5 VLW-10 VLW-15 VLW-20 VLW-25 VLW-30 VLW-40 Performance characteristics

Capacity*

ton 5.1 9.1 11.5 15 19 24 27 40 Compressor number x Hp {kW} 5 {3.7} 7.5 {5.6} 10 {7.5} 15 {11} 2x10 {15} 2x13 {19} 2x15{22} 40 {29} Pump Hp {kW} 2 {1.5} 2 {1.5} 2 {1.5} 3 {2.2} 3 {2.2} 5 {3.7} 5 {3.7} 7.5 {5.6} Chilled water flow✝gpm {lpm} 12{45} 22 {83} 28 {106} 36 {136} 48 {182} 60 {227} 72 {273} 92 {348} Chilled water pressure✝psi {bar} 63 {4.34} 58 {4} 57 {3.9} 45{3.1} 41 {2.83} 59 {4.07} 57 {3.93} 61 {4.2} Reservoir capacity gal {liters} 25 {95} 25 {95} 25 {95} 65 {246} 65 {246} 65 {246} 65 {246} 65 {246} Compressor type Scroll Scroll Scroll Scroll Scroll Scroll Scroll Semi-hermetic

Condenser water requirements

‡

City gpm {lpm} 7 {26} 14 {53} 17 {64} 23 {87} 30 {114} 38 {106} 45 {170} 60 {227} Tower gpm {lpm} 15 {57} 28 {106} 35 {132} 45 {170] 60 {227} 75 {284} 90 {341} 170 {644} Dimensions in {mm} Height 40 {102} 40 {102} 40 {102} 57 {1448} 57 {1448} 57 {1448} 57 {1448} 57 {1448} Width 32 {813} 32 {813} 32 {813} 34 {864} 34 {864} 34 {864} 34 {864} 34 {864} Depth 40 {102} 40 {102} 40 {102} 40 {102} 56 {1422} 80 {2032} 80 {2032} 80 {2032} Pipe size NPT in. Process (to and from) 1.25 1.25 1.25 1.5 1.5 2.0 2.0 2.5 Make-up (optional) 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 Condensing 0.75 1.0 1.0 1.25 1.25 1.25 1.5 2.0 Weight lb {kg} Shipping 550 {249} 600 {318} 625 {283} 1500 {680} 1900 {862} 2100 {953} 2200 {998} 2500 {1134} Voltages running/full load amps§run full run full run full run full run full run full run full run full 230V/3 phase/60hz 22 26 32 40 38 48 54 68 58 72 58 72 90 114 126 166 460V/3 phase/60hz 11 13 16 20 19 24 27 34 29 36 29 36 45 57 63 83 575V/3 phase/60hz 9 9 13 16 16 19 22 22 24 24 24 24 36 36 5 5

Refrigerant Type HCFC-22

MODEL VLW-2 VLW-3 Performance characteristics

Capacity* ton 2 3 Compressor Hp {kW} 2 {1.5} 3 {22} Pump Hp {kW} 0.75 {0.56} 0.75 {0.56} Chilled water flow✝gpm {lpm} 4.8 {18} 7.2 {27} Chilled water pressure✝psi {bar} 40 {2.76} 39 {2.69} Reservoir capacity gal {liters} 15 {56.8} 15 {56.8} Compressor type Hermetic Hermetic

Condenser water requirements

‡

City gpm {lpm} 6 {23} 9 {34} Tower gpm {lpm} 3 {11} 4.5 {17} Dimensions in {mm} Height 30 {762} 30 {762} Width 24 {610} 24 {610} Depth 37 {940} 37 {940} Pipe size NPT in. Process (to and from) 0.75 0.75 Make-up (optional) 0.5 0.5 Condensing 0.5 0.5 Weight lb {kg} Shipping 445 {202} 470 {213} Voltages running/full load amps§run full run full 230V/3 phase/60hz 12 12 17 17 460V/3 phase/60hz 6 6 8 8 575V/3 phase/60hz — — — — Refrigerant Type HCFC-22

VLW MODELS, 2 TO 40 TONS

Page: 66

VL Series Portable Chillers, 2 to 40 Tons UGH021/0301

8.2 OPERATION BELOW 48°F

A. A chiller typically operates with a setpoint of 50°F or higher.

However, if setpoints between 20° - 48°F are required, special precautions must be taken to prevent freezing and possible damage. Attention must be given to freeze protection, water supply and safety adjustments.

B. FREEZE PROTECTION

1. It is understood that untreated water freezes at 32°F.

Therefore, an inhibited propylene glycol and water solution must be used in lieu of ordinary water. Prescribed amounts are listed in figure 8.2A.

2. On initial installation of the unit, the water/glycol solution should be premixed, then added to the reservoir. After the pump has been started, water lines filled and air purged, it may be necessary to add more water/glycol solution to maintain the recommended reservoir level. Note: a hygrometer should be used on a regular basis to determine the mixture strength according to freeze point. The freeze point temperature should be 25° below the lowest required setpoint. Water will evaporate from the mixture, and if you continue to add a premixed solution eventually you will have too much glycol. It is necessary to add water or glycol to maintain proper freeze point temperature.

3. PLEASE NOTE THAT A CHILLER IS NOT DESIGNED TO ACCOMMODATE AUTOMOTIVE TYPE ANTI-FREEZE. This

is due to the fact that automotive type anti-freeze contains silicates that adhere to heat transfer surfaces of the system preventing maximum heat transfer. Also, improper portions of inhibited propylene glycol to water inhibits effective heat transfer. Consult the chiller’s operating manual for specific details.

C. WATER SUPPLY

1. The automatic water supply (if equipped) restores the

reservoir water level as needed. However, if untreated water is added to an water/glycol solution, dilution will occur

OPERATING ANTI-FREEZE MIXTURE

TEMPERATURE GLYCOL WATER

40°F 20% 80% 25°F 25% 75% 30°F 30% 70%

Figure 8.2A

UGH021/0301 VL Series Portable Chillers, 2 to 40 Tons

Page: 67

decreasing the freeze protecting ability of the solution. Therefore, the water supply source must be disconnected and the connection capped. The operator must monitor the water/glycol level and manually make-up to maintain proper reservoir level.

D. SAFETY ADJUSTMENTS

1. To ensure safe and efficient operations at lower setpoints,

adjustments of the freezestat and low pressurestat factory settings are required. Figure 8.2B lists the appropriate settings.

2. The freezestat serves as the mainline defense against freezing in that it shuts down the chiller if the coolant temperature ever decreases to its setting. For mechanical freezestats, adjustments are made by removing the cover and rotating the selector dial with a screwdriver. Electronic freezestats are adjusted through the setup parameters via the instrument control panel.

3. The low pressurestat serves to protect the compressor from unsafe suction pressures. Suction pressures decrease with lower operating setpoints. To prevent short cycling of the compressor, the low pressurestat must be adjusted to accommodate the lower setpoint. Adjustments to the low pressurestat are made by rotating the adjusting screws on top of the control and observing the movement of the pointers in the control window until the prescribed setting is determined.

E. PRECAUTIONS

1. 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.

Figure 8.2B

Page: 68

VL Series Portable Chillers, 2 to 40 Tons UGH021/0301

8.3 WATER QUALITY CONTROL

A. Lack of, as well as, improper water treatment can damage the

chilling unit. The services of a competent water treatment specialist should be obtained and their recommendations followed. It is the equipment owner’s responsibility to prevent damage from foreign material or inadequate water treatment.

B. The two main things to consider for water treatment in chillers are

corrosion and organism growth. Proper chemical treatment can control PH levels and algae growth. An alternative to chemical treatment is the addition of 20% inhibited propylene glycol to the water. This will help prevent organism growth and coat the heat transfer surfaces with corrosion inhibitor.

8.4 INHIBITED PROPYLENE GLYCOL

A. The use of a water-glycol

mixture is needed when the operator desires a process temperature below 48°F. Freeze protection is required so ice crystals do not form and cause severe damage to both the water and refrigeration system.

B. CHOOSING THE PROPER

GLYCOL:

1. For getting the most efficiency from your system, a

propylene glycol such as “DowFrost” is a must. DowFrost contains special corrosion inhibitors for low system maintenance and better transfer capabilities than normal glycols. It also has a much longer fluid life up, to 20 years in some cases.

2. SOURCES OF INHIBITED PROPYLENE GLYCOLS: for a complete literature package, material, safety data sheets and purchasing information, contact the following:

DOW CHEMICAL 1-800-447-4369 (Canada 1-800-363-6250) Dowfrost inhibited propylene glycol

MONSANTO CHEMICAL 1-800-459-2665 Monsanto FS inhibited propylene glycol

FREEZING POINTS FOR

WATER/PROPYLENE GLYCOL SOLUTIONS

PERCENTAGE OF

100

0 10 20 30 40 50 60

*PROPLYLENE GLYCOL

NOTE: GLYCOL FREEZE POINT MUST BE 25˚F BELOW

LOWEST SETPOINT

FREEZE POINT

90 80 70 60 50 40

˚F

32 25 10

-10

-30

-60

˚CWATERGLYCOL*

-3.9

-12.2

-17.8

-23.3

-34.4

-51.4

UGH021/0301 VL Series Portable Chillers, 2 to 40 Tons

Page: 69

C. USE OF PLAIN GLYCOL:

1. Even through they do lower the freeze point, plain glycols

are even more corrosive than water. The corrosion rate of plain ethylene glycol on iron, for example, is more than 2.5 times faster than plain water. On steel, it is 4.5 times faster.

D. AUTOMOTIVE BASED ANTIFREEZE:

1. SHOULD NEVER BE USED!

Automotive antifreeze contains silicate based inhibitors, which are compatible with automotive components. In an industrial application, the silicates will leach out and form a gel-like substance on the heat transfer surfaces and reduce cooling efficiency of the system. These silicates have shown to significantly reduce the lifetime of pump seals.

E. MAINTENANCE RESPONSIBILITY:

1. A hygrometer should be used on a regular basis to

determine the mixture strength according to freeze point. The freeze point temperature should be 25°F below the lowest required setpoint (see chart on page 59). Water will evaporate from the mixture, and if you continue to add a premixed solution, eventually you will have too much glycol. It is necessary to add water or glycol to maintain proper freeze point temperature. The device pictured is by far the most accurate and easy to use for maintaining and checking for proper glycol levels.reduction in cooling capacity and is virtually impossible to remove.

Page: 70

VL Series Portable Chillers, 2 to 40 Tons UGH021/0301

8.5 MAINTAINING PROPER WATER FLOW

A. The evaporator in a typical

water chiller is flow sensitive. That is, the efficiency of operation is directly related to the flow of liquid. Maximum efficiency is obtained at approximately

2.4gpm per ton of rated capacity. Low liquid flow can reduce efficiency and in some cases allow ice to form in the evaporator which can damage the evaporator.

B. The Conair one pump chiller

system is designed so that all process flow must pass through the evaporator. If the process flow is less than the 2.4 gpm required, then it will be necessary to install a low flow bypass system in the process lines (see section

8.6). This will allow a portion of the process flow to bypass the process and return directly to the chiller to keep the total flow above the 2.4 gpm per ton requirement.

C. To assure proper flow on central chillers. Conair installs a low flow

safety switch to stop the refrigeration system if the liquid flow falls to approximately 33% of full flow. This is a paddle type flow switch which is mounted directly in the water stream.

The evaporator is the heat exchanger where in the refrigeration circuit that allows the liquid refrigerant to absorb heat from the water. As the heat is absorbed, the liquid refrigerant changes state from liquid to vapor, and the water is chilled.

21 GPM 5 GPM

BYPASS

CHILLER PROCESS

THROTTLING VALVE 16 GPM

5 GPM21 GPM

UGH021/0301 VL Series Portable Chillers, 2 to 40 Tons

Page: 71

8.6 LOW FLOW BYPASS CIRCUITS

A. In cases of restricted flow or reduced capacity conditions, as an

option Conair supplies manual or automatic low flow bypass circuits on water cooled or air cooled portable chillers. It is recommended that where low flow conditions exist, a bypass system be installed either in the field or by Conair. It is the ultimate responsibility of the user to make sure adequate flow through the evaporator is achieved.

B. The low flow bypass circuit, whether automatic or manual, is

designed to provide the chiller with the proper amount of flow through the chiller’s evaporator continually. This prevents default on the low flow safety switch in times of restricted flow or reduced capacity.

C. AUTOMATIC low flow bypass circuits place a pressure actuated

valve between the from process and to process lines. Conair presets the valve to open at the pump’s dead head pressure to prevent overloading and to provide proper flow to the evaporator at all times.

D. MANUAL low flow bypass circuits place a ball valve between the

from process and to process lines. The valve is shipped in the closed position. The valve is then field adjusted based on process requirements.

AUTOMATIC BYPASS DIAGRAM

MANUAL BYPASS DIAGRAM

FILTER-DRIER

HIGH PRESSURE SAFETY SWITCH

COMPRESSOR

LIQUID LINE

SOLENOID VALVE

WATER COOLED CONDENSER

FILTER-DRIER

HIGH PRESSURE SAFETY SWITCH

COMPRESSOR

LIQUID LINE

SOLENOID VALVE

WATER COOLED CONDENSER

LOW PRESSURE SAFETY SWITCH

HOT GAS

BYPASS VALVE

REFRIGERANT

SIGHT GLASS

LOW PRESSURE SAFETY SWITCH

HOT GAS

BYPASS VALVE

REFRIGERANT SIGHT GLASS

EXPANSION VALVE

WATER REGULATOR VALVE

CONDENSER WATER IN

PORT CONNECTION

CONDENSER WATER OUT

PORT CONNECTION

EVAPORATOR

RESERVOIR TANK

COOLANT PUMP

WATER REGULATOR VALVE

RESERVOIR TANK

EVAPORATOR

COOLANT PUMP

LEVEL SWITCH

(OPTIONAL)

MAKE-UP

SOLENOID VALVE

(OPTIONAL)

TO PROCESS

SENSOR PROBE

CONDENSER WATER IN

PORT CONNECTION

SERVICE LID

SOLENOID VALVE

TO PROCESS

SENSOR PROBE

SERVICE LID

CONDENSER WATER OUT

PORT CONNECTION

LEVEL SWITCH

(OPTIONAL)

MAKE-UP

(OPTIONAL)

WATER MAKE-UP

CONNECTION

(OPTIONAL)

FROM PROCESS

PORT CONNECTION

PRESSURE ACTIVATED VALVE

TO PROCESS

PORT CONNECTION

WATER MAKE-UP

CONNECTION

(OPTIONAL)

PORT CONNECTION

AUTOMATIC BYPASS

FROM PROCESS

PORT CONNECTION

MANUAL BYPASS VALVE

TO PROCESS

Page: 72

VL Series Portable Chillers, 2 to 40 Tons UGH021/0301

8.7 OVERHEAD PIPING KIT

A. Conair portable chillers have between a 4.5 to 60 gallon reservoir

capacity (depending on chiller size). When a Conair portable chiller is used with overhead piping, the chiller tank will overflow upon shut-down due to the drainback of water volume from the overhead piping system (which exceeds the tank capacity of the chiller). If the piping arrangement is not above the chiller tank level, then this problem will not exist.

B. To prevent tank overflow, an overhead piping kit should be

installed. This kit is available from Conair as an option and factory installed, or can be field retrofitted.

C. The overhead piping kit places a solenoid valve on the FROM

PROCESS line and a check valve on the TO PROCESS line. The

solenoid valve is activated by an auxiliary contact on the process pump motor starter.

D. During operation, when the pump is on, the solenoid valve on the

FROM PROCESS line opens to allow flow to the chiller. The check will open due to the flow generated by the pump on the TO PROCESS line.

E. During shut down, the solenoid valve will close preventing flow to

the tank. The check valve will close as well. With both valves closed, water in the overhead piping system can not flow back to the chiller causing the chiller to overflow.

FILTER-DRIER

HIGH PRESSURE SAFETY SWITCH

COMPRESSOR

LIQUID LINE

SOLENOID VALVE

WATER COOLED CONDENSER

LOW PRESSURE SAFETY SWITCH

HOT GAS

BYPASS VALVE

REFRIGERANT SIGHT GLASS

EXPANSION VALVE

WATER REGULATOR VALVE

CONDENSER WATER IN

PORT CONNECTION

CONDENSER WATER OUT

PORT CONNECTION

EVAPORATOR

RESERVOIR TANK

COOLANT PUMP

SOLENOID VALVE

TO PROCESS

SENSOR PROBE

SERVICE LID

LEVEL SWITCH

(OPTIONAL)

MAKE-UP

(OPTIONAL)

FROM PROCESS

PORT CONNECTION

SOLENOID VALVE

MAKE-UP PORT

CONNECTION (OPTIONAL)

TO PROCESS

PORT CONNECTION

CHECK VALVE

UGH021/0301 VL Series Portable Chillers, 2 to 40 Tons

Page: 73

8.8 CHILLER CAPACITY AND DERATE CHART

-5

* * * * *

105%

100%

90%

80%

70%

60%

50%

40%

30%

22%

15%

OUTPUT

TEMPERATURE

°F

FULL AVAILABLE % CAPACITY

NOTES:

If operation of the chiller at less than 48°F is required, an inhibited propylene glycol solution is required.

Consult factory for chiller operation below 20°F.

Ambient conditions affect air cooled chiller operation and capacity. Standard rating is at 95°F entering air temperature. For ambient air conditions greater than 95°F, chiller derating will occur. For ambients of 95-105°F, select the next larger capacity chiller. For ambients over 105°F, consult factory.

* These ranges require special options.

Standard chiller rating is at 50°F. For all other temperature settings,

output tonnage is altered as follows:

Page: 74

VL Series Portable Chillers, 2 to 40 Tons UGH021/0301

8.9 PRESSURE-TEMPERATURE CHART FOR R-22 REFRIGERANT

SATURATED TEMPERATURE

40°F

45°F

50°F

55°F

60°F

65°F

70°F

75°F

80°F

85°F

90°F

95°F

100°F

FREON PRESSURE

100

112

122

132

144

156

168

182

196

THESE PRESSURE/TEMPERATURE RELATIONSHIPS ARE IN AN

AT-REST, SA

TURATED CONDITION. FOR EXAMPLE, IF THE UNIT HAS BEEN IN A WAREHOUSE AT 40° AND IS

BROUGHT INTO A ROOM WHERE IT IS 80°, IT MAY TAKE A COUPLE OF HOURS FOR THE UNIT TO WARM UP AND

THE PRESSURE TO RISE TO THE SURROUNDING AMBIENT CONDITIONS.

UGH021/0301 VL Series Portable Chillers, 2 to 40 Tons

Page: 75

8.10 ENGINEERING FORMULAS

1 ton = 12,000 btu BTU = Material (lbs) X material 's specific heat X temperature difference 1 BTU = .293 watts 1 watt = 3.42 BTU 1 KW = 1000 watts 1 KW = 3420 BTUs BTU/hr = GPM X T (for water cooled condensers)

TONS =

1 Gallon of Water = 8.34 lbs

1 Pound of Water = .1198 gallon 1 Cubic foot of Water = 7.481 gallons

1 HP = 2546.5 BTU/hr

1 HP =

GPM (water) X 8.34 X 60 X temperature difference X specific heat

GPM (water) X T

12,000

= 231 cubic inch = .1337 cubic feet = 3.785 liters = 4 quarts

= 62.37 pounds

= 745.7 watts = 42.442 BTU/min

PSI X GPM

1199

Feet of Head X GPM x Specific Gravity

2772

PSI = .4331 X Feet of Head

PSI =

1 Foot of Head = .4332 PSI Feet of Head = PSI X 2.3

Watts = Amps X Volts (single phase)

Volts = Ohms X Amps

Volts =

Feet of Head

2.3

= Amps X Volts X 1.73 (three phase)

Watts Amps

Volts = Watts X Ohms

1 KVA = (three phase)

1 KVA = (single phase)

CFM =

KW =

F = (9/5 X C) +32 C = 5/9 X ( F - 32) Volume of Cylinder = Circumference of Circle = Diameter of Circle X Diameter of Circle = Circumference X .3183 Area of Circle =

1 Gram = .0353 oz 1 Foot = 30.48 centimeter 454 Gram = 1 lb 1 Oz = 28.35 grams 1 Kilogram-calorie = BTUH X .252 1 Millimeter = inches X 25.4 1 Kilogram = Lbs X .454 1 Square Centimeter = .155 square inch 1 Square Inch = 6.452 sqaure centimeter

Amps X Volts X 1.73

1000

Amps X Volts

1000

KW X 300

Temperature Difference

Tons X 10530

Temperature Difference

CFM X Temperature Difference

3000

X R2 X L

D2 X .7854

TO CONVERT

FROM TO Multiply by:

UNIT VOLUME

liters/min

US GPM

cum/hr

US GPM

liters/min

CFM

cum/hr

CFM

UNIT WEIGHT

gr/sq cm

Lbs/sq in

kPA

Lbs/sq in

kg/sq cm

Lbs/sq in

gr/cu cm

Lbs/cu in

LENGTH

Inches

cm meters

Feet

meters

Yards

Miles

VOLUME

cu cm

Cu inches

liters

Cu inches

cu meters

Cu feet Cu feet

liters

Cu years

cu meters

Fl ounces

cu cm

US gal

liters

-17.8

-15

-12.2

-9.4

-6.7

1.1

35 40 45 50 55 60

0 5 10 15 20 30

TO CONVERT

FROM TO Multiply by:

POWER

3.785

FT/LB/SEC

.2271

28.317

Boiler HP

1.6992

HP HP

HEAT

70.31 BTU

6.894 BTU/LB

.07031

BTU/SQ FT

27.68 BTU/CU FT

2.540

WEIGHT

.3048

Grains

.9144

Ounces*

1.609 Pounds*

US tons

16.387 US tons

.01639

Long tons

.02832

AREA

28.317 Sq inches

.7646

Sq years

29.57 Sq miles

3.785

*Auoirdupois pounds and ounces

TEMPERATURE

1.7

4.4

F to C = ( F - 32) x .55 = C

7.2

10.0

C to F = ( C x 1.8) + 32 = F

12.8

15.6

watts BTUH BTUH BTUH kw

kg-cal kg-cal gr-cal/sq cm kg-cal/cum

grams grams kg lg tonnes kg

sq cm sq meters sq km

ABBREVIATIONS, EQUIVALENTS & FORMULAS

METRIC CONVERSION TABLE

PSI = Pounds Per Square Inch GPM = Gallons Per Minute EWT = Entering Water Temperature LWT = Leaving Water Temperature BTU = British Thermal Unit BTU/HR = GPM x 500 x T (water) FT. H.D. = PSI x 2.31 1 COOLING TOWER TON = 15,000BTU/HR 1 REFRIGERANT TON = 12,000 BTU/HR

1 GALLON = 8.33 lbs (water) 1 CUBIC FOOT = 7.48 gallons TOWER CELL EVAPORATION RATE = 2 gal. per ton per hour

NOMINAL DESIGN FLOW

COOLING TOWER = 3 GPM PER TON CHILLING = 2.4 GPM PER TON

WEIGHED WATER TESTS

CHILLER TON =

GPM x T

#/min x T

200

TOWER TON =

CHILLER SIZING

INJECTION MOLDING

30#/hr H.D. Polyethylene = 1 ton 35#/hr L.D. Polyethylene = 1 ton 35#/hr Polypropylene = 1 ton 75#/hr PVC = 1 ton 50#/hr ABS = 1 ton 50#/hr Polystyrene = 1 ton 40#/hr Nylon = 1 ton 35#/hr Acrylic = 1 ton 40#/hr Polyurethane = 1 ton 50#/hr Acetal = 1 ton 40#/hr PPO = 1 ton 40#/hr PET = 1 ton 50#/hr Polycarb = 1 ton

EXTRUSION

45#/hr H.D. Polyethylene = 1 ton 45#/hr L.D. Polyethylene = 1 ton 45#/hr Polypropylene = 1 ton 75#/hr Polystyrene = 1 ton 70#/hr PVC = 1 ton

BLOWN FILM

105 CFM

(50 F air @ 78 F WBT)

BLOW MOLDING

40#/hr Polyolefins = 1 ton

OTHER EQUIPMENT

AIR COMPRESSOR w/no aft cooler = .1 TON/HP

AIR COMPRESSOR w/aft cooler = .2 TON/HP

CHILLER CAPACITY LOSS =

PIPE SIZING GUIDE

VACUUM PUMP = .1 TON/HP

HYDRAULIC COOLING = .1 TON/HP

BARREL COOLING = 1 TON/IN SCREW DIA.

2% for each 1 F below 50 F LWT

(based on 5'-7' feet/second velocity)

1/2" = 6 GPM 3/4" = 10 GPM

1" = 15 GPM 1 1/4" = 30 GPM 1 1/2" = 40 GPM

2" = 70 GPM

2 1/2" = 100 GPM

3" = 150 GPM 4" = 275 GPM 6" = 600 GPM 8" = 1,000 GPM

1.356 3420 33475 2545 .7457

.252 .5556 .2713

8.899

.0648

28.350 .4536

907.2 .9072 1016

6.452 .8361

2.590

GPM x T

#/min x T

250

= 1 ton

Page: 76

VL Series Portable Chillers, 2 to 40 Tons UGH021/0301

8.11 SPARE PARTS LIST - WATER COOLED MODELS

PART # DESCRIPTION

820000 Caster 4” Swivel

830000 Caster 4” Rigid 1197000 Compressor BRH2-1000-TFD-219 1515500 Condenser 45” x 46

”

1733700 Auxiliary Contact CR305X200B (nc) 1825020 Contactor CR305D002 2190000 Filter Drier C-415S 2900006 Evaporator 75-30H 10ton 2940000 Expansion valve PVE-11 CP100 2996009 Fan F10S08A2230-5 3190000 Freezestat A19ABC-24 3400000 Fuse block Gould #30352 3708505 Plastic Handle P2-41 4341886 Instrument Kit #213400 Flat display ‘VL’ 4341879 Instrument only #246100 Flat display ‘VL’ 6205500 Temperature sensor #902300 7163580 Electronic filter ‘quench arc’ #933400 4714403 Fan motor 3/4hp 1075 RPM 6210600 Motor/pump assembly 1ST1G200 G&L 2HP

433 Adapter #1L87

4310513 Impeller #2L46 6

”

5404000 Lock nut (impeller) #13K6 6495035 Pump seal kit #RPK1ST G&L 9117700 Volute #1L81 6900000 See-All SA-15S 7180000 Solenoid Valve B6S1 1163300 Coil #MKC-1 7200000 Solenoid Valve B10S2 1163000 Coil #MKC-2 7370000 Motor starter CR354AB3AA1B 1733456 Auxiliary contact kit 7558000 Low pressure safety P70AB-2 7558500 High pressure safety P70DA-1 8067600 Terminal block PWR DIST #1423570 8244000 Transformer 9T58B43 8837515 Bypass valve 2P072

”

8990000 Relief valve 400 PSI

UGH021/0301 VL Series Portable Chillers, 2 to 40 Tons

Page: 77

8.12 SPARE PARTS LIST - AIR COOLED MODELS

PART # DESCRIPTION

820000 Caster 4” Swivel

830000 Caster 4” Rigid 1197000 Compressor BRH2-1000-TFD-219 1515500 Condenser 45” x 46

”

433 Adapter #1L87

4310513 Impeller #2L46 6

”

8990000 Relief valve 400 PSI

VL Series Portable Chillers, 2 to 40 Tons UGH021/0301

Page: 78

THIS PAGE INTENTIONALLY BLANK

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.

To contact Customer Service personnel, call:

From outside the United States, call: 814-437-6861

You can commission Conair service personnel to provide onsite service by contacting the Customer Service Department. Standard rates include an on-site hourly rate, with a one-day minimum plus expenses.

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

❒ Make sure you have all model, serial 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.

BEFORE YOU CALL ...

HOW TO

CONTACT CUSTOMER SERVICE

Additional manuals and prints for your Conair equipment may be ordered through the Customer Service or Parts Departments for a nominal fee.

WE’RE HERE

HELP

UGH021/0301 VL Series Portable Chillers, 2 to 40 Tons

Page: 79

QUIPMENT

GUARANTEE

PERFORMANCE WARRANTY

WARRANTY LIMITATIONS

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.

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 adjust-

ments 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 equip-

ment that will meet original performance claims at no extra cost to the customer.

● Refund the invoiced cost to the customer. Credit is sub-

ject 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.

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.

VL Series Portable Chillers, 2 to 40 Tons UGH021/0301

Page: 80

Conair VL Series, VLA-7.5, VLA-10, VLA-15, VLA-20 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual