Conair W1-1.5, W1-2, W1-3, W1-4, W1-5 User Manual

Instant Access

Parts and Service

[phone]
[phone]

www.conairnet.com

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

UGH017/0500

Installation

Operation

Maintenance

Troubleshooting

Portable Chillers

Series 1 Water-Cooled (W1) and
Air-Cooled (A1) Models with PLC Control

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: UGH017/0500

Serial number(s):

Model number(s):

Power specifications:

Amps
Volts
Phase
Cycle

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

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

Please record your

equipment’s model and

serial number(s) and

the date you received it

in the spaces provided.

Copyright 2000

All rights reserved

THE CONAIR GROUP, INC.

UGH017/0500 Series 1 Portable Chillers, PLC Control

TABLE OF
CONTENTS

INTRODUCTION . . . . . . . . . . . . . . . . . . .1-1

Purpose of the User Guide . . . . . . . . . . . . . . . . . . . . . . . . .1-2

How the Guide is Organized . . . . . . . . . . . . . . . . . . . . . . .1-2

Your Responsibilities as a User . . . . . . . . . . . . . . . . . . . . .1-2

ATTENTION: Read this so no one gets hurt . . . . . . . . . . .1-3

DESCRIPTION . . . . . . . . . . . . . . . . . . . .2-1

What is the Portable Chiller? . . . . . . . . . . . . . . . . . . . . . . .2-2

Typical Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-3

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

How it Works: Water-cooled Portable Chiller . . . . . . . . . .2-4

How it Works: Air-cooled Portable Chiller . . . . . . . . . . . .2-6

Portable Chiller Features . . . . . . . . . . . . . . . . . . . . . . . . . .2-8

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-10

Pump Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-12

INSTALLATION . . . . . . . . . . . . . . . . . . . .3-1

Unpacking the Boxes . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2

Warnings and Cautions . . . . . . . . . . . . . . . . . . . . . . . . . . .3-3

Preparing for Installation . . . . . . . . . . . . . . . . . . . . . . . . . .3-4

Making Process Plumbing Connections . . . . . . . . . . . . . . .3-5

Filling the Chiller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-6

Checking Refrigerant Charge . . . . . . . . . . . . . . . . . . . . . . .3-8

Connecting the Main Power Source . . . . . . . . . . . . . . . . . .3-9

Checking Electrical Connections . . . . . . . . . . . . . . . . . . .3-10

Initially Starting the Chiller . . . . . . . . . . . . . . . . . . . . . . .3-10

Checking for Leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-12

Connecting the Remote Control . . . . . . . . . . . . . . . . . . . .3-13

Stopping the Chiller . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-13

OPERATION . . . . . . . . . . . . . . . . . . . . . .4-1

PLC Control Features . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2

Before Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-3

Powering Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-4

Running/Stopping the Chiller . . . . . . . . . . . . . . . . . . . . . . .4-5

Viewing Chiller Status . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-6

Programming Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-8

Changing Setpoint Temperature . . . . . . . . . . . . . . . . . . . .4-9

Resetting PID Settings . . . . . . . . . . . . . . . . . . . . . . . . . . .4-10

Changing High Temperature Deviation . . . . . . . . . . . . . .4-11

Setting Percent Glycol . . . . . . . . . . . . . . . . . . . . . . . . . . .4-12

Setting Fan Setpoints . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-14

Setting Auto Tune Mode . . . . . . . . . . . . . . . . . . . . . . . . .4-16

Manually Starting/Stopping the Pump . . . . . . . . . . . . . . .4-18

i

Series 1 Portable Chillers, PLC Control UGH017/0500

TABLE OF
CONTENTS

M

AINTENANCE . . . . . . . . . . . . . . . . . . . .5-1

Maintenance Features . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-2

Warnings and Cautions . . . . . . . . . . . . . . . . . . . . . . . . . . .5-3

Preventative Maintenance Schedule . . . . . . . . . . . . . . . . . .5-4

Entering Maintenance Screens . . . . . . . . . . . . . . . . . . . . . .5-6

Checking Electrical Connections . . . . . . . . . . . . . . . . . . . .5-8

Cleaning the Evaporator or Water-cooled Condenser . . . . .5-9

Cleaning the Air-cooled Condenser . . . . . . . . . . . . . . . . .5-10

Checking the Refrigerant Charge . . . . . . . . . . . . . . . . . . .5-11

Checking Reservoir Level . . . . . . . . . . . . . . . . . . . . . . . .5-12

TROUBLESHOOTING

. . . . . . . . . . . . . . . .6-1

Before Beginning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-2

A Few Words of Caution . . . . . . . . . . . . . . . . . . . . . . . . . .6-3

Identify the Cause of a Problem . . . . . . . . . . . . . . . . . . . . .6-3

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

Control Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-6

Alarm Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-8

Checking and Replacing Switches . . . . . . . . . . . . . . . . . .6-16

Checking the Pressure Transducer . . . . . . . . . . . . . . . . . .6-17

Checking the Temperature Transmitter and RTD . . . . . . .6-18

Replacing the RTD . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-20

Replacing the Temperature Transmitter . . . . . . . . . . . . . .6-21

Removing Pump Components . . . . . . . . . . . . . . . . . . . . .5-22

Replacing Overload Modules . . . . . . . . . . . . . . . . . . . . . .6-23

Replacing Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-24

Replacing the Contactor . . . . . . . . . . . . . . . . . . . . . . . . . .6-25

Replacing the PLC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-26

APPENDIX . . . . . . . . . . . . . . . . . . . . . .A-1

Customer Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-1

Maintenance Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-1

Pressure Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-1

PARTS AND DIAGRAMS . . . . . . . . . . . .P/D-1

ii

1-1

Series 1 Portable Chillers, PLC Control UGH017/0500

●●

Purpose of the User Guide . . . .1-2

●●

How the Guide is Organized . . .1-2

●●

Your responsibilities as a user .1-2

●●

ATTENTION: Read this so

no one gets hurt . . . . . . . . . . .1-3

INTRODUCTION

Series 1 Portable Chillers, PLC Control UGH017/0500

1-2 INTRODUCTION

This User Guide describes Conair’s Series 1 Water-cooled and
Air-cooled Portable Chillers and explains step-by-step how to
install, operate, maintain and repair this equipment.

Before installing this product, please take a few moments to
read the User Guide and review the diagrams and safety infor­mation in the instruction packet. You also should review man­uals covering associated equipment in your system. This
review won’t take long, and it could save you valuable instal­lation and operating time later.

Symbols have been used to help organize the User Guide and
call your attention to important information regarding safe
installation and operation.

Symbols within triangles warn of conditions that could
be hazardous to users or could damage equipment.
Read and take precautions before proceeding.

Numbers within shaded squares indicate tasks or steps
to be performed by the user.

A diamond indicates the equipment’s response to an
action performed by the user.

An open box marks items in a checklist.

A shaded circle marks items in a list.

You must be familiar with all safety procedures concerning
installation, operation and maintenance of this equipment.
Responsible safety procedures include:

● Thorough review of this User Guide, paying particular

attention to hazard warnings, appendices and related dia­grams.

● Thorough review of the equipment itself, with careful

attention to voltage sources, intended use and warning
labels.

● Thorough review of instruction manuals for associated

equipment.

● Step-by-step adherence to instructions outlined in this

User Guide.

P

URPOSE OF

THE

USER

GUIDE

HOW THE
G

UIDE IS

ORGANIZED

1

◆

❒

●

YOUR
RESPONSIBILITY

AS A

USER

UGH017/0500 Series 1 Portable Chillers, PLC Control

INTRODUCTION 1-3

We design equipment with the user’s safety in mind. You can
avoid the potential hazards identified on this machine by fol­lowing the procedures outlined below and elsewhere in the
User Guide.

ATTENTION:

READ THIS SO NO

ONE GETS HURT

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

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

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

WARNING: Electrical hazard

Before performing any work on this item, dis­connect and lock out electrical power sources to
prevent injury from unexpected energization or
startup.

CAUTION: Hot Surfaces

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

CAUTION: Ventilation hazard

The unit requires a clean and well ventilated
operating environment. Do not place anything
on top of the unit while operating. Units with
fans require unrestricted outlet air flow.

Water-cooled units require a minimum of one
foot clearance around the perimeter for service­ability. Air-cooled units require a minimum of two
feet clearance around the perimeter for service­ability and proper air flow.

2-1

Series 1 Portable Chillers, PLC Control UGH017/0500

●●

What is the Portable Chiller? . . .2-2

●●

Typical Applications . . . . . . . . . .2-3

●●

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

●●

How it Works: Water-cooled

Portable Chiller . . . . . . . . . . .2-4

●●

How it Works: Air-cooled

Portable Chiller . . . . . . . . . . .2-6

●●

Portable Chiller Features . . . . . .2-8

●●

Specifications . . . . . . . . . . . . .2-10

●●

Pump Curves . . . . . . . . . . . . . .2-12

DESCRIPTION

The Conair Series 1 Portable Chillers provide self-contained
sources of chilled water and are available in either water- or
air-cooled models. Ranging in size from 1.5 Hp to 13 Hp in
the air-cooled configuration and 1.5 Hp to 15 Hp in the water­cooled design [approximate capacities of 1.5 tons of refrigera­tion to 15 tons of refrigeration]. Pump selections are available
to match most process flow and pressure requirements.

The normal temperature range of discharge chilled water is
20 °F (7 °C) to 70 °F (21 °C). For applications requiring tem­peratures of 40 °F (4 °C) and lower, mix glycol with the
water to the correct percentage.

The Air-cooled Portable Chiller A1 Models and Water-cooled
Portable Chiller W1 Models are designed to provide chilled
fluid for industrial applications requiring 24-hour-a-day per­formance. Units are totally self-contained for easy, economical
installation. All parts wetted by the process are non-ferrous.

To operate, simply connect the power source, process piping
and fill with water or with industrial grade ethylene glycol or
propylene glycol (but not automotive antifreeze).

These chillers are ideal for machine-side cooling to maintain
process temperatures in an injection molding machine or
extruder and wherever you need a small, portable cooling unit.
Nominal capacities range from 1.44 to 14.68 tons for the
water-cooled models and from 1.18 to 10.95 tons for the air­cooled models. Capacities are based on standard pump sizes
and delivering 50 °F (10 °C) water.

Operation of these units differ only in the medium used to
remove heat from the refrigerant in the condensers. Water­cooled models use 85 °F (29 °C) or lower cooling water from
a tower, well, or city service; air-cooled models use 95 °F
(35 °C) maximum ambient air.

Choose Water-cooled Portable Chillers where tower water or
another inexpensive water source is available. Choose Air­cooled models for maximum portability of the unit. Water­cooled models are equipped with brazed plate or tube-in-tube
condensers. Air-cooled models use aluminum-fin, copper-tube
condensers.

All standard voltages are available.

WHAT IS THE
PORTABLE
CHILLER?

Series 1 Portable Chillers, PLC Control UGH017/0500

2-2 DESCRIPTION

The Conair A1 and W1 Portable Chillers can be used any­where a reliable source of process cooling water - with stable
temperature control - is required.

These portable chillers are available for cooling injection
molding, blow molding, thermoforming, extrusion, air com­pressors, metal plating, anodizing, degreasing, heatset/web
offset printing presses, and dryer after-coolers.

Roll the air-cooled condenser models next to the heat source
connect it and plug it in. They can operate almost anywhere.

The water-cooled condenser models require a source of con­denser water. Normally used in conjunction with a recirculat­ing evaporative cooling tower system, the units have slightly
better operating energy efficiencies.

TYPICAL
APPLICATIONS

UGH017/0500 Series 1 Portable Chillers, PLC Control

DESCRIPTION 2-3

L

IMITATIONS

Conair Series 1 Portable Chillers are designed to provide
chilled water for industrial applications requiring 24-hour-a­day performance. Units are self-contained and easy to install
and maintain. Choose the Conair Series 1 Portable Chillers
based on the cooling load and the capacity of the unit. Pick
your Conair Series 1 Portable Chillers based on:

● Cooling load

Choose a portable chiller that has 20% more capacity than
the process load.

● Location

Choose a water-cooled model if the unit will be located in
an air-conditioned area and a source of condenser water is
readily available (i.e. cooling tower water). Do not locate
either portable chiller model outside unless the unit is
specially modified.

● Temperature

The portable chiller has a standard setpoint temperature
range of 20 °F (7 °C) to 70 °F (21°C).

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

HOW IT WORKS:
W

ATER-COOLED

PORTABLE
CHILLER

Series 1 Portable Chillers, PLC Control UGH017/0500

2-4 DESCRIPTION

Process circulation

Pump draws water

from pump reservoir
and moves it through the
strainer and flow switch to
the evaporator.

2

Hot fluid from the

process enters the
chiller through the From
Process valve into the
pump reservoir.

1

Fluid is chilled in the

evaporator and exits
through the To Process
valve and tube, returning to
the process.

3

HOW IT WORKS:
W

ATER-COOLED

CONT’D

UGH017/0500 Series 1 Portable Chillers, PLC Control

DESCRIPTION 2-5

The liquid refrigerant

leaves the accumula­tor, passing through the
thermal expansion valve,
where it expands and
cools.

4

Refrigerant circulation

The high pressure vapor travels from

the compressor through the coiled
condenser (where it is condensed into a
liquid) and is stored in the accumulator.

3

Vaporized refrigerant

travels from evapora­tor to the compressor,
where the low pressure
vapor is compressed into
a high pressure vapor.

2

The evaporator extracts heat

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

1

Cooled refrigerant is metered
back into the exaporator for

the cycle to begin again.

5

HOW IT WORKS:
A

IR-COOLED

PORTABLE
CHILLER

Series 1 Portable Chillers, PLC Control UGH017/0500

2-6 DESCRIPTION

Process circulation

Fluid is chilled in the

evaporator and exits
through the To Process
valve and tube, returning to
the process.

3

Hot fluid from the

process enters the
chiller through the From
Process valve into the
pump reservoir.

1

Pump draws fluid

from pump reservoir
and moves it through the
strainer and flow switch to
the evaporator.

2

UGH017/0500 Series 1 Portable Chillers, PLC Control

DESCRIPTION 2-7

HOW IT WORKS:
A

IR-COOLED

CONT’D

Refrigerant circulation

The evaporator extracts heat

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

1

Cooled refrigerant is metered
back into the exaporator for

the cycle to begin again.

5

Vaporized refrigerant

travels from evapora­tor to the compressor,
where the low pressure
vapor is compressed into
a high pressure vapor.

2

The liquid refrigerant
leaves the accumulator,
passing through the ther­mal expansion valve,
where it expands and
cools.

4

The high pressure vapor
travels from the compressor
through the condenser (where
fans cool vapor into a liquid)
and liquid is stored in the
accumulator.

3

Series 1 Portable Chillers, PLC Control UGH017/0500

2-8 DESCRIPTION

PORTABLE
CHILLER
FEATURES

Receiver

stores the liquid refrigerant.

Filter dryer

cleans and dries the refrig­erant.

From Process
connection

Relief valve

acts as a safety
device for refrig­erant pressure.

Condenser

condenses the refrig­erant from a high
pressure vapor into a
high pressure liquid.

Liquid line solenoid
valve

pumps down refrigerant
to the receiver.

Temperature trans­mitter electrical box

transmits temperature
signals to the control

Process pump

circulates process fluid
through the chiller.

Compressor

compresses the refrig­erant from a low pres­sure vapor into a high
pressure vapor.

Hot Gas Bypass valve

balances the load on the
chiller to meet the needs of
the process.

To Process connection

TX valve

regulates refrigerant flow

Evaporator

cools the process fluid

Pump reservoir

stores process fluid. View fluid
level on water level gauge

Options include:

● 60 Hz process pump with:

1 1/2 Hp for W1-1.5, W1-2
2 Hp for W1-3, W1-4
3 Hp for W1-5, W1-7.5, W1-10, W1-15

● To Process and From Process valves

● Process bypass line and valve

● No reservoir/pump

● No reservoir

● Auto fill reservoir (for non-glycol systems)

● Condenser water differential pressure switch (W1-7.5 to

W1-15 only)

● Visual alarm

● Audible alarm

● Remote/redundant hand control with 30 ft. cable

● Remote/redundant hand control with 50 ft. cable

● UL labeled controls

Water-cooled Models

UGH017/0500 Series 1 Portable Chillers, PLC Control

DESCRIPTION 2-9

Air-cooled Models

PORTABLE
CHILLER
FEATURES

Fans

circulate air across the con­denser to cool refrigerant

Receiver

stores the liquid refrigerant.

Filter dryer

cleans and dries the refrigerant.

Hot Gas Bypass valve

balances the load on the
chiller to meet the needs of
the process.

To Process connection

Evaporator

cools the process fluid

Liquid line solenoid
valve

pumps down refrigerant
to the receiver.

Temperature trans­mitter electrical box

transmits temperature
signals to the control

Process pump

circulates process fluid
through the chiller.

Compressor

compresses the refriger­ant from a low pressure
vapor into a high pres­sure vapor.

TX valve

regulates refrigerant flow

Condenser

compresses the refrigerant
from a high pressure vapor
into a high pressure liquid.

Options include:

● 60 Hz process pump with:

1 1/2 Hp for A1-1.5, A1-2.25
2 Hp for A1-3.25, A1-4
3 Hp for A1-5, A1-7.5, A1-10, A1-13

● To Process and From Process valves

● Process bypass line and valve

● Condenser air filters

● No reservoir/pump

● No reservoir

● Auto fill reservoir (for non-glycol systems)

● Visual alarm

● Audible alarm

● Remote/redundant hand control with 30 ft. cable

● Remote/redundant hand control with 50 ft. cable

● UL labeled controls

Pump reservoir

stores process fluid. View fluid
level on water level gauge

From Process
connection

Series 1 Portable Chillers, PLC Control UGH017/0500

2-10 DESCRIPTION

Water-cooled Models

SPECIFICATIONS

front

side back

B

A

C

D

E

F

10 {254}

9 {229}

10.5 {267}

5.5 {140}

MODEL W1-1.5 W1-2 W1-3 W1-4 W1-5 W1-7.5 W1-10 W1-15
Performance characteristics

Capacity✝, tons 1.44 1.93 3.23 4.44 5.00 7.09 10.22 14.68
Compressor Hp {kW} 1.5 {1.1} 2 {1.5} 3 {2.2} 4 {3} 5 {3.7} 7.5 {5.6} 10 {7.5} 15 {11}
Pump Hp {kW}

60 Hz 0.75 {0.6} 0.75 {0.6} 1 {.8} 1 {0.8} 1.5 {1.1} 1.5 {1.1} 1.5 {1.1} 2 {1.5}

50 Hz 1.5 {1.1} 1.5 {1.1} 1.5 {1.1} 2 {1.5} 2 {1.5} 2 {1.5} 2 {1.5} 2 {1.5}
Chilled water flow‡, gpm {lpm} 6.9 {25.1} 4.6 {17.4} 7.8 {29.5} 10.7 {40.5} 12.0 {45.4} 17.0 {64.3} 24.5 {92.7} 35.2 {133.2}
Chilled water pressure§, psi {bar} 27.8 {1.9} 29.9 {2.1} 32.9 {2.3} 31.8 {2.2} 41.6 {2.9} 34.8 {2.4} 29.3 {2.0} 32.3 {2.2}
Reservoir capacity, gal {l} 8.0 {30.3} 15 {57} 15 {57} 15 {57} 15 {57} 25 {95} 25 {95} 25 {95}
Condenser water flow, gpm {lpm} 5.0 {18.9} 6.4 {24.2} 10.3 {39.0} 14.2 {53.7} 16.7 {63.2} 24.1 {91.2} 31.7 {120} 45.4 {172}
Dimensions in {mm}
A-Height 49 {1245} 49 {1245} 61 {1549}
B-Width 34 {864} 34 {864} 34 {864}
C-Length 39.5 {1003} 45.5 {1156} 55 {1397}
D-Height to Condenser Out 37 {940} 38.5 {978} 38.5 {978} 38.5 {978} 38 {965} 41.3 {1049} 41.3 {1049 41.3 {1049}
E-Height to Condenser In 31 {787} 32.5 {826} 32.5 {826} 32.5 {826} 32 {813} 35 {889} 35 {889} 35 {889}
F-Distance to Valve 4 {102} 4.5 {114}
Weight lb {kg}
Installed

420 {190} 585 {265} 585 {265} 840 {381} 840 {381} 1080 {490} 1090 {494} 1095 {497}

Shipped 550 {249}

755 {342} 755 {342} 1010 {458} 1010 {458} 1250 {567} 1260 {572} 1265 {574}

Utility requirements

Process connections, in 1 1.5
Condenser water, in 1 1.5
Power consumption, amps run full run full run full run full run full run full run full run full

230V/3 phase/60hz* 9.5 15.3 10.2 15.6 15.1 24.4 18.7 29.4 22.5 36.3 29.2 44.7 35.0 56.0 44.8 79.0

220V/3 phase/50hz 13.1 19.1 13.8 19.4 17.8 27.5 22.5 33.6 24.3 38.6 31.3 47.4 37.4 59.1 46.8 82.1

460V/3 phase/60hz* 4.5 6.9 4.9 7.1 7.3 11.1 9.1 13.3 10.9 16.4 14.2 20.2 17.1 25.3 22.0 35.7

575V/3 phase/60hz* 3.6 5.5 3.9 5.7 5.8 8.9 7.3 10.7 8.7 13.1 11.4 16.2 13.7 20.2 17.6 28.5

SPECIFICATION NOTES

✝

Based on 50 °F (10 °C) water temperature (100% water) leaving the chiller, standard pump selections, 85 °F (27 °C) condenser water supply

@ 25 psi minimum, for the 60 Hz units. For the 50 Hz units, multiply the capacity by 0.8 Consult factory for other conditions. Capacity ratings

are (+-) 5% based on compressor manufacturer’s ratings and are subject to change without notice.

‡

Based on 50° F (10 °C) water temperature leaving the chiller and 60 °F (16 °C) water temperature returning to the chiller (except W1-1.5

which has 55 °F (13 °C) water temperature returning to the chiller).

§

Pressure at pump discharge. See Pressure Tables in the Appendix for evaporator and condenser pressure drops.

* Optional

Air-cooled Models

SPECIFICATIONS

UGH017/0500 Series 1 Portable Chillers, PLC Control

DESCRIPTION 2-11

A

B

C

front

side

back

10 {254}

9 {229}

10.5 {267}

5.5 {140}

SPECIFICATION NOTES

✝

Based on 50 °F (10 °C) water temperature (100% water) leaving the chiller, standard pump selections, 95 °F (35 °C) ambient air conditions for

the 60 Hz units. For the 50 Hz units, multiply the capacity by 0.8. Consult factory for other conditions. Capacity ratings are (+-) 5% based on
compressor manufacturer’s ratings and are subject to change without notice.

‡

Based on 50 °F (10 °C) water temperature leaving the chiller and 60 °F (16 °C) water temperature returning to the chiller (except A1-1.5 and

A1-2.25 which have 55 °F (13 °C) water temperature returning to the chiller).

§

Pressure at pump discharge. See Pressure Tables in the Appendix for evaporator and condenser pressure drops.

* Optional

MODEL A1-1.5 A1-2.25 A1-3.25 A1-4 A1-5 A1-7.5 A1-10 A1-13
Performance characteristics

Capacity✝, tons 1.18 1.79 2.77 3.62 4.27 6.06 8.75 10.95
Compressor Hp {kW} 1.5 {1.1} 2.25 {1.7} 3.25 {2.4} 4 {3} 5 {3.7} 7.5 {5.6} 10 {7.5} 13 {9.7}
Pump Hp {kW}

60 Hz 0.75 {0.6} 0.75 {0.6} 1 {.8} 1 {0.8} 1.5 {1.1} 1.5 {1.1} 1.5 {1.1} 2 {1.5}

50 Hz 1.5 {1.1} 1.5 {1.1} 1.5 {1.1} 2 {1.5} 2 {1.5} 2 {1.5} 2 {1.5} 2 {1.5}
Chilled water flow‡, gpm {lpm} 5.7 {21.6} 8.6 {32.6} 6.7 {25.4} 8.7 {32.9} 10.2 {38.6} 14.5 {54.9} 21.0 {79.5} 26.3 {99.6}
Chilled water pressure§, psi {bar} 29.6 {2.0} 28.5 {2.0} 35.9 {2.5} 33.9 {2.3} 42.4 {2.9} 36.9 {2.5} 31.6 {2.2} 36.1 {2.5}
Reservoir capacity, gal {l} 8.8 {33.3} 15 {57} 15 {57} 15 {57} 15 {57} 25 {95} 25 {95} 25 {95}
Condenser Fans 1 2 2 2 2 2 2 4
Condenser fan power, Hp {kW} 0.17 {0.13} 0.17 {0.13} 0.17 {0.13} 0.25 {0.19} 0.25 {0.19} 0.5 {0.4} 0.5 {0.4} 0.5 {0.4}
Condenser air flow, 1050 1704 2420 4237 4237 5300 5300 9800

ft3/min {lpm} {29,732} {48,250} {68,525} {119,975} {119,975} {150,075} {150,075} {277,505}
Dimensions in {mm}
A-Height 49 {1245} 49 {1245} 53.5 {1359} 71 {1524} 75 {1905}
B-Width 34 {864} 34 {864} 34 {864} 34 {864} 34 {864}
C-Length 39.5 {1003} 45.5 {1156} 55 {1397} 55 {1397} 55 {1397}
Weight lb {kg}
Installed

610 {277} 830 {376} 830 {376} 1030 {467} 1030 {467} 1230 {558} 1230 {558} 1440

{653}

Shipped 750 {340}

1000 {454} 1000 {454} 1200 {544} 1200 {544} 1400 {635} 1600 {726} 1800 {816}

Utility requirements

Process connections, in 1 1.5
Power consumption, amps run full run full run full run full run full run full run full run full

230V/3 phase/60hz* 11.0 19.6 13.3 20.8 18.6 32.2 23.7 33.3 27.8 40.1 38.6 47.2 47.2 62.7 57.4 76.9

220V/3 phase/50hz* 14.7 23.6 17.1 24.8 21.5 35.5 27.7 37.6 29.9 42.6 41.2 50.0 50.2 66.1 60.0 79.9

460V/3 phase/60hz 5.3 8.9 6.5 9.4 9.0 14.6 11.6 15.1 13.5 18.2 18.9 21.4 23.2 28.4 28.3 34.8

400v/3 phase/50hz* 7.7 11.8 9.0 12.4 11.4 17.8 14.8 18.8 16.0 21.3 22.2 25.0 27.2 33.0 32.6 40.0

575V/3 phase/60hz* 4.2 7.1 5.2 7.5 7.2 11.7 9.3 12.1 10.8 14.5 15.1 17.1 18.6 22.7 22.6 27.8

Series 1 Portable Chillers, PLC Control UGH017/0500

2-12 DESCRIPTION

PUMP CURVES

Flow Rate (gpm)

Pressure (psi)

60 HZ PUMP PERFORMANCE CURVES

50 HZ PUMP PERFORMANCE CURVES

Pressure (psi)

Flow Rate (gpm)

3-1

Series 1 Portable Chillers, PLC Control UGH017/0500

●●

Unpacking the Boxes . . . . . . . . . .3-2

●●

Warnings and Cautions . . . . . . . . .3-3

●●

Preparing for Installation . . . . . . .3-4

●●

Making Process Plumbing

Connections . . . . . . . . . . . . . . . .3-5

●●

Filling the Chiller . . . . . . . . . . . . . .3-6

●●

Checking Refrigerant Charge . . . .3-8

●●

Connecting the Main

Power Source . . . . . . . . . . . . . . .3-9

●●

Checking Electrical Connections 3-10

●●

Initially Starting the Chiller . . . . .3-10

●●

Connecting the Remote Control .3-11

●●

Checking for Leaks . . . . . . . . . . .3-12

●●

Stopping the Chiller . . . . . . . . . .3-13

INSTALLATION

The portable chiller comes fully assembled in a single crate.

UNPACKING THE
BOXES

Series 1 Portable Chillers, PLC Control UGH017/0500

3-2 INSTALLATION

CAUTION: Lifting

The Series 1 Portable Chillers are designed to
easily roll on casters. If, for some reason you
need to lift the chiller, take all precautions to
avoid personal injury or damage to the chiller.
Lift the chiller using a forklift or hoist with straps
that have been positioned about the chillers’
center of gravity. Do not try to lift the unit manu­ally.

Carefully uncrate the chiller

and its components.

Remove all packing material, protective paper,

tape, and plastic. Compare contents to the shipping papers
to ensure that you have all the parts.

Carefully inspect all components to make sure

no damage occurred during shipping. If any damage is
found, notify the shipping agent immediately. Check all
wire terminal connections, bolts, and any other electrical
connections, which may have come loose during ship­ping. Check for pinched wires and kinked hoses.

Record serial numbers and specifications

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

1

2

3

4

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

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

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

CAUTION: Hot Surfaces

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

CAUTION: Ventilation

The unit requires a clean and well ventilated
operating environment. Do not place anything
on top of the unit while operating. Units with
fans require unrestricted outlet air flow.

Water-cooled units require a minimum of one
foot clearance around the perimeter for service­ability. Air-cooled units require a minimum of two
feet clearance around the perimeter for service­ability and proper air flow.

WARNING: Refrigerant hazard

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

WARNINGS AND
CAUTIONS

UGH017/0500 Series 1 Portable Chillers, PLC Control

INSTALLATION 3-3

PREPARING FOR
INSTALLATION

Series 1 Portable Chillers, PLC Control UGH017/0500

3-4 INSTALLATION

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

Position the Chiller as close to the process machine as possi­ble. Place the chiller in position near the process machine so
that fluid lines can be connected from the process machine to
the chiller and back.

Chiller

Process machine

Alternate
locations

24 inches

(610 mm)

24 inches

(610 mm)

● Available water source.

If installing a water-cooled unit, make sure condenser
water source is plumbed to chiller installation location.
High points in plumbing require vent valves; low points
require drain valves.

Make sure the area where the chiller is installed has:

● A grounded power source.

Check the chiller’s serial tag for the correct amps, volt­age, phase, and cycle. All wiring should be completed by
qualified personnel and comply with your region’s electri­cal codes.

● Clearance for safe operation and maintenance.

Make sure there is two feet clearance around the chiller
for proper operation, maintenance, and servicing. After
positioning, lock casters to prevent chiller from moving.

24 inches

(610 mm)

24 inches

(610 mm)

UGH017/0500 Series 1 Portable Chillers, PLC Control

INSTALLATION 3-5

MAKING
PROCESS
PLUMBING
CONNECTIONS

Warm fluid from process equipment enters the chiller at the
From Process connection and chilled fluid returns to the
process equipment through the To Process connection.

Remove the shipping plastic pipe plug from

the female connections on the back of the portable chiller.

Make sure the male pipe threads are clean

and new.

Wrap threads with Mylar or Teflon tape.

Connect the From Process connection on the

back of the chiller to the From Process hose. Start by
hand until the threads engage and then tighten with a pipe
wrench. Tighten only enough to prevent leaks; do not
over-tighten!

Connect the To Process connection on the

back of the chiller to the return hose. Start by hand until
the threads engage and then tighten with a pipe wrench.
Tighten only enough to prevent leaks; do not over-tighten!

For Water-cooled Chillers connect the cooling water source to
the Condenser Water inlet on the back of the chiller. Connect
the Condenser Water outlet to the cooling water source’s
return.

1

2

3

4

5

back view

Condenser

Water outlet

(water-cooled only)

Condenser

Water onlet

(water-cooled only)

To Process
connection

From Process
connection

If you unit does not have
the optional To Process
valve and From Process
valve, you may want to
install valves on the To
Process and From
Process connections to
more easily control
process fluid into and
out of the chiller.

The Chiller is shipped without coolant. The chiller is filled
manually during installation. Use water as the coolant down to
40 °F (4 °C). Below 40 °F and down to 20 °F (-7 °C), use an
ethylene glycol or propylene glycol solution.

To fill with water:

Attach water hose to Fill/Drain valve.

Close the To Process and From Process valves.

Open the Fill/Drain valve and fill chiller

to the fill mark on the Water Level gauge. If the chiller is
overfilled, the excess water spills out the vent tube.
DO NOT OVERFILL.

Close the Fill/Drain valve.

Disconnect water hose from Fill/Drain valve.

Series 1 Portable Chillers, PLC Control UGH017/0500

3-6 INSTALLATION

1
2

3

4
5

Water level
gauge

Fill/Drain valve

To Process
connection

From Process
connection

FILLING THE
CHILLER

To fill with glycol solution:

Mix the glycol to the proper percentage.

Use the table to determine the percentage (by volume) of
glycol needed for the process temperature (in °F) you
require. Do not choose a temperature below 15 °F (-9 °C).
Mix the proper percentage of glycol with water.

1

UGH017/0500 Series 1 Portable Chillers, PLC Control

INSTALLATION 3-7

FILLING THE
CHILLER

CONT’D

Temperature of Process Fluid

°

F

Glycol, % by Volume

Close the To Process and From Process valves.

Open the Fill/Drain valve and fill chiller

to the fill mark on the Water Level gauge. If the chiller is
overfilled, the excess fluid spills out the vent tube. DO
NOT OVERFILL.

Close the Fill/Drain valve.

Check the coolant level.

Once the chiller is turned on, the coolant level may drop
as the coolant begins to circulate, filling the connected
plumbing. Check the coolant level on the back of the
chiller. The coolant level shows on the water level gauge.
Make sure coolant level is filled to the mark on the gauge.

Set the Chiller control for ‘Percent Glycol’.

Set the percent glycol using the PLC control (see Setting
Percent Glycol, in the Operation section). Do this step
after main power is connected to the chiller and initial
startup has already been performed.

2
3

4
5

6

CHECKING
REFRIGERANT
CHARGE

Series 1 Portable Chillers, PLC Control UGH017/0500

3-8 INSTALLATION

All chillers are fully charged with refrigerant at the factory.
Your chiller’s model nameplate identifies the type and amount
of total refrigerant charge required.

Check refrigerant charge while the chiller is running. Check
the refrigerant charge through the site glass. For water-cooled
models open the side panel; for air-cooled models, locate the
site glass through the wire mesh side panel. Use a flashlight, if
necessary, and check the site glass:

● Under full load conditions, the refrigerant should be

clear (no bubbles).

● Under low load conditions, when the hot-gas bypass

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

If the charge is low contact Conair service or have a local, cer­tified refrigeration technician add refrigerant to the system.

Sight
glass

WARNING: Refrigerant hazard

Only certified refrigerant technicians should
examine and correct problems involving the
refrigerant circuit.
If your Chiller is still under warranty you must
Contact Conair Service before contacting a con­tractor to service your Chiller.

UGH017/0500 Series 1 Portable Chillers, PLC Control

INSTALLATION 3-9

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

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

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

WARNING: Electrical hazard

Before performing any work on this item, dis­connect and lock out electrical power sources to
prevent injury from unexpected energization or
startup.

Open the chiller’s electrical enclosure.

Connect the power wires

to the terminals (see the wiring
diagrams that came with your
machine). Route the power
cable through the hole in the
side of the chiller to the elec­trical enclosure.

Check terminal screws

to make sure wires are secure.
Gently tug each wire; if wire is loose, use a
screwdriver to tighten the terminal.

Connect the ground wire to grounding lug.

1
2

3

4

Grounding
lug

The 575V, 1 1/2 - 4 Hp
units utilize a transformer;
power wires must be con­nected to the line side of
the transformer.

CONNECTING

THE

MAIN

POWER SOURCE

Series 1 Portable Chillers, PLC Control UGH017/0500

3-10 INSTALLATION

Conair Chiller

A1 - 5

I

NITIALLY

STARTING THE
CHILLER

Turn on main power source.

The control boots up and the screen displays the Portable
Chiller model number.

CHECKING
ELECTRICAL
CONNECTIONS

If you disconnect the Chiller
from the main power supply
and reconnect it, the Chiller
needs 15 minutes for the
crankcase heater to warm
up. You can not use the
Chiller during this time.

Open electrical enclosure.

Check the short-to-ground with an ohm meter.

Connect the ohm meter to each of the three terminal
screws and to the grounding lug. Test all three for resis­tance. The maximum resistance to ground should be 1
megohm. If it resistance is more than 1 megohm there is a
leak in the system.

WARNING: Electrical hazard

Before performing any work on this item, dis­connect and lock out electrical power sources to
prevent injury from unexpected energization or
startup.

1
2

Test each for
resistance

Close the electrical enclosure.

The Chiller is now ready for initial startup.

3

Grounding
lug

WARNING: Initial startup

Do not press any buttons after initially applying
power to the Chiller. Let the Chiller set, undis­turbed, for a minimum of 8 hours before starting
the Chiller. This is necessary to allow the
crankcase heater to warm properly, and to pre­vent the refrigerant from pooling in the com­pressor.

1