FTS RS Series Operator's Manual

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Page 1

RSSeriesChillers

Operator’sManual

             

FTS

3538 Main Street

Stone Ridge, NY 12484 USA

(800) 824-0400 or 001 (845) 687-0071

www.SPIndustries.com

SP Service:

(877) 548-4666 or 001 (645) 687-5400

FAX: (845) 687-0024

E-Mail: [email protected]

Document #MNL-008-A, Rev. 009

Page 2

Notice

This Operation Manual contains confidential and proprietary information of SP Industries, Inc. and may be used only by a recipient designated by and for purposes specified by SP Industries, Inc.

Reproduction of, dissemination of, modifications to, or the creation of derivative works from this manual, by any means and in any form or manner, is expressly prohibited, except with the prior written permission of SP Industries, Inc. Permitted copies of this document must retain all proprietary notices contained in the original.

The information in this document is subject to change without prior notice. Always confirm with SP Industries, Inc. that you are using the most current version of this document. SP Industries, Inc. is free to modify any of its products and services, in any manner and at any time, notwithstanding the information contained in this document.

THE CONTENTS OF THIS DOCUMENT SHALL NOT CONSTITUTE ANY WARRANTY OF ANY KIND, EITHER EXPRESSED OR IMPLIED, INCLUDING BUT NOT LIMITED TO THE IMPLIED WARRANTIES OF MERCHANTABILITY AND/OR FITNESS FOR A PARTICULAR PURPOSE OR GIVE RISE TO ANY LIABILITY OF SP INDUSTRIES, INC., ITS AFFILIATES OR ITS SUPPLIERS.

The terms and conditions governing the use of this Operation Manual shall consist of those set forth in written agreements with SP Industries, Inc.

All brand or product names mentioned may be trademarks or registered trademarks of their respective companies.

Page 3

Contents

Contents........................................................................................................................................ iii

Important Symbols........................................................................................................................ 4

Foreword ........................................................................................................................................ 5

Safety Precautions...................................................................................................................................... 5

Inspection ................................................................................................................................................... 6

Introduction.................................................................................................................................... 7

Model Number Identification .................................................................................................................... 7

Installation...................................................................................................................................... 8

Physical Location..................................................................................................................................... 8

Ambient Air Requirements ....................................................................................................................... 8

Selecting a Process Fluid ........................................................................................................................... 9

Process Fluid Properties.........................................................................................................................10

Electrical Requirements.............................................................................................................................11

High pressure Bypass Hook-Up (Accessory).............................................................................................12

Connect to the Process .............................................................................................................................13

Operation...................................................................................................................................... 14

User Menu .................................................................................................................................... 16

User Menu Layout .....................................................................................................................................17

Proportional Control Menu.........................................................................................................................18

Span Menu ................................................................................................................................................19

Miscellaneous Menu ..................................................................................................................................20

Communications Menu ..............................................................................................................................21

High Fluid Temperature .............................................................................................................................22

Low Fluid Temperature..............................................................................................................................23

PID Tuning.................................................................................................................................................24

IT and DT...................................................................................................................................................25

CCT ...........................................................................................................................................................25

CPB ...........................................................................................................................................................26

HPB, CPB, AND DB ..................................................................................................................................27

RS-232 Communications Programmer's Reference ................................................................ 28

Maintenance................................................................................................................................. 42

Troubleshooting .......................................................................................................................... 47

Service..........................................................................................................................................50

FTS Warranties and Service Agreements .................................................................................................50

Standard Warranty.....................................................................................................................................51

Service Options .........................................................................................................................................52

Extended Warranty: ................................................................................................................................52

Preventative Maintenance: .....................................................................................................................52

Service Contract: ....................................................................................................................................52

Return of FTS Equipment ..........................................................................................................................53

iii

Page 4

ImportantSymbols

FTS designs and manufactures units to be safe and reliable systems. Safety features are

incorporated throughout and appropriate signs and symbols are provided. In this manual,

safety issues are addressed in context. Users are strongly encouraged to become familiar

with these symbols.

Warning! Refer to manual text. Injury or even death may result if a recommendation marked with this symbol is not heeded.

Electric Shock Danger! Use appropriate caution to avoid injury or death.

Burn Danger! Potentially hot surface. Use appropriate caution.

Do not store flammable materials in chamber.

Wear Safety Glasses.

Crush Hazard. Keep hands clear when operating door.

Corrosive Chemical. Wear suitable gloves, safety glasses, and protective

clothing.

Property Caution! To prevent damage to chamber equipment and/or load, adhere to procedures marked by this symbol.

Practical Operating Tip. These recommendations streamline unit operation and prevent common operator errors.

Page 5

Foreword

Thank you for buying an SP Industries / FTS product. Our goal is 100 percent customer

satisfaction. If you are in any way dissatisfied with your order, please contact us immediately.

Safety Precautions

Your satisfaction and safety will be assured by a complete understanding of this equipment.

To assure your satisfaction and safety, as end user of this equipment, it is the operator’s

responsibility to understand its function and operational characteristics. Before operating this

equipment please read this instruction manual thoroughly. Ensure that all operators receive

appropriate training.

Awareness of the stated cautions and warnings, compliance with recommended operating

parameters, and performance of periodic maintenance requirements are important for safe

and satisfactory operation.

Your instruction and maintenance manual is valuable as it contains information to help you

better understand and operate the equipment you have purchased. It includes a wiring

diagram and contact numbers, which you may require at some future date. Keep it close at

hand and refer to it often. Additional manuals may be purchased from our Parts Department.

If any part of these instructions is not clearly understood, please feel free to contact Customer

Service for clarification.

If you require replacement parts, we must have the model and serial numbers plus all

electrical information from the nameplate.

CAUTION

As a routine safety precaution, always wear safety glasses when working with this equipment.

The unit should be used for its intended application; alterations or modifications will void the

warranty. This product is not intended, nor can it be used, as a sterile or patient-connected

device, nor is it designed for use in Class I, II, or III locations as defined by the National

Electrical Code.

WARNING! FOLLOW THESE INSTRUCTIONS TO AVOID INJURY AND/OR DAMAGE TO EQUIPMENT.

Never use with toxic, corrosive, flammable or organic materials unless special precautions are in place to prevent injury to personnel or damage to equipment.

Never operate unit without all covers in place.

Never clean with solvents. Use mild detergent and water only.

Never allow hands or body to be exposed to open vacuum ports.

Always verify that the electric service and other utilities match the unit’s requirements before

connecting to power.

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Operator’s Manual: RS Series Chiller Foreword

Always wear safety glasses when using glass flasks.

Always practice team lifting when moving heavy equipment.

Always ensure that refrigeration air intake is clear and clean.

Always ensure that only an authorized technician services the refrigeration, heat transfer,

vacuum and electrical systems.

Always assume that internal parts may be very cold or very hot. Utilize personal protective equipment to avoid burns.

Inspection

This merchandise was carefully packed and thoroughly inspected before leaving our factory.

Save all packing material if apparatus is received damaged.

Responsibility for its safe delivery is assumed by the carrier upon acceptance of the

shipment, therefore, claims for loss or damage sustained in transit must be made upon the

carrier by recipient as follows:

Visible loss or damage

Note any external evidence of loss or damage on the freight bill, or express receipt, and have

it signed by the carrier's agent. Failure to adequately describe any such external evidence of

loss or damage may result in carrier's refusing to honor your damage claim. The form

required to file such a claim will be supplied by the carrier.

Concealed loss or damage

Concealed loss or damage means loss or damage which does not become apparent until the

merchandise has been unpacked and inspected. Should either be discovered, make a written

request for inspection by the carrier's agent with 15 days of the delivery date; then file a claim

with the carrier since the damage is the carrier's responsibility. By following these instructions

carefully, we guarantee our full support of your claim to be compensated for loss from

concealed damage.

Do not -- for any reason -- return this unit without first obtaining authorization. Please

supply nameplate data, including model number and serial number, in any

correspondence to the manufacturer.

DO NOT STORE OR PROCESS FLAMMABLE MATERIALS This unit is not designed (nor is it intended to be used) for the purpose of processing or storage of materials that may contain volatile flammable solvents or that may emit flammable vapors during processing or storage.

WARNING

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RS Series Chillers are portable, caster mounted systems that provides temperature controlled fluid over a wide range. All FTS chillers feature innovative design, high-quality construction, and high reliability components. This chiller will reliably serve your cooling needs for years to come.

Features include:

•Small Footprint

•Digital / RS-232 Control

•+/- 0.1°C stability

•Wide Temperature Range

•Mechanical Refrigeration (Air- Cooled)

hapter

Introduction

Model Number Identification

Copy the model number into the appropriate line below. Use the chart to check the options that have been built into the unit. The model number is listed on the serial tag on the rear of the unit.

RS33 Recirculator, 1/3HP

Voltage

Low Temp Capability

Heater

Pump

Voltage

Low Temp Capability

Pump

A 120V / 60Hz D 220V / 50Hz

0 -10°C Low Temp L -40°C Low Temp

0 No Heater 1 600W Heater (+75°C High Temp)

02GPM, 4psi 1 1.6GPM, up to 100°C

RS44 Recirculator, 1/3HP

B 230V / 60Hz C 208V / 60Hz D 220V / 50Hz

0 -10°C Low Temp L -40°C Low Temp

02GPM, 4psi 2 1.6GPM, up to 100psi

Page 8

Installation

Physical Location

The area where you place the unit should be smooth, level, and capable of safely supporting

the weight of the machine. Space should be provided so that air can properly circulate around

the unit. If obstacles are blocking the airflow, the compressor may overheat. This reduces

performance, and can lead to early compressor failure.

The environment should be well ventilated to prevent excessive build up of heat. Normal

room ventilation is usually adequate.

Ambient Air Requirements

This unit is designed for operation in a normal indoor environment. (Systems should not be

mounted outside or otherwise exposed to the elements). The environment should be free

from air containing large amounts of moisture, salt or sulfur. If your system utilizes an air-

cooled condenser, the fan in the system draws ambient air across the condenser (radiator) to

cool the refrigerant.

The ambient air temperature requirements are:

Chapter

55°F to 69°F (12°C to 21°C) 70°F to 75°F (21°C to 24°C)

75°F to 80°F (24°C to 27°C).

80°F to 85°F (27°C to

29.5°C) Over 85°F (Over

29.5°C)

Acceptable

Ideal

Acceptable, but a reduction in the cooling capacity of the unit is to be expected (about a 1% cooling capacity reduction per degree above 72°F).

Expect reduced reliability. Warranty may be voided.

Not Acceptable. Warranty will be voided.

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Operator’s Manual: RS Series Chiller Chapter 2: Installation

Fluid Temp Range(°C) Flammability Toxicity Dielectric

Glycol/Water 60/40 Glycol/Water/Methanol 60/30/10

Methanol -80/0 Medium Low Low Ethanol -60/0 Medium Medium Low Syltherm XLT -60/200 Low Very Low High Silicone 1.0 -55/200 Low Very Low High

-30/60

-50/30

Low

Selecting a Process Fluid

This recirculator is designed for operation with a host of industry standard fluids. Which fluid you choose will depend partly on what temperature range you require. Ethylene Glycol and water (60/40 mix) is an inexpensive and readily available fluid for –25°C to +60°C. If you require a fluid outside this temperature range, FTS suggests using HT-30 Silicone Oil for –60°C to +100°C.

There are other fluids available, but to avoid potential application problems and to speed troubleshooting; it is suggested that one of the fluids mentioned above be used. DO NOT USE AUTOMOTIVE ANTI-FREEZE (it contains clotting agents) If for some reason one of the above fluids is not suitable, and you select a different one, be sure that it has a viscosity of less than 20 centistokes over the full temperature range of the unit. NOTE: All of the above mentioned fluids have viscosity of less than 20 centistokes across their useable temperature ranges.

Since most systems have capability to achieve temperatures below 0°C, water should

not be used as a process fluid.

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Operator’s Manual: RS Series Chiller Chapter 2: Installation

Process Fluid Properties

Expansion/Contraction

It is important to note that some fluids expand as much as 14% from +25°C to +125°C. Do not confuse contraction of the fluid for fluid losses. Also, open the red vent screw on the reservoir lid when changing the setpoint (the temperature the unit controls at).

Fluid Creep

Galden and similar fluids are very 'thin' and any non-sealed connection in the fluid loop will leak.

Dissolved Gases

At room temperature the fluid contains dissolved gas. As the fluid temperature is increased the amount of dissolved gas decreases dramatically, causing excess gas to be released from the fluid. This release of gas should not be mistaken for boiling of the fluid.

W ate r S o lub ility

Process fluids are water-soluble. After long periods of operation at low temperatures, water from the air will condense on and mix with the fluid. this decreases the performance of the system. To remove the excess water, warm the fluid to room temperature and pump the fluid through a molecular sieve or desiccant material. Alternately, simply run the system at temperatures over 100°C, this will boil off any water present in the fluid. (Only applies to the systems that are capable of temperatures over 100°C)

Low surface tension and high vapor pressure

This means that the fluid evaporates very easily and that any improperly sealed joints will leak. Close the red vent screw on the reservoir lid to prevent excessive evaporation of the fluid, but remember to open the vent screw when changing setpoints (the fluid expands and contracts with temperature changes).

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Operator’s Manual: RS Series Chiller Chapter 2: Installation

Electrical Requirements

Only qualified personnel should perform the installation of this unit.

The voltage and frequency requirements are specified on the serial tag on the rear of the unit. Standard variances in frequency (+/-3Hz) and voltage (-5%, +10%) are allowed.

•Verify that the facilities voltage matches the requirement for the machine, which is

printed on the serial tag on the rear of the machine.

•The electric service wiring must be of a large enough wire gauge that the voltage is

maintained to the receptacle even when a full load is applied to the receptacle.

Additionally, the receptacle voltage should be measured while that receptacle is under load.

•This unit has a NEMA 5-15P or 6-15P line cord, install an appropriate (NEMA 5-

15R or 6-15R) receptacle where the unit is to be run. (some 50 Hz machines are shipped with no plug)

•Ensure the proper amperage circuit breaker is installed in the line and located near

the equipment.

•Plug in the line cord. (Avoid the use of long extension cords, these cause a

significant power drop between the wall receptacle and the machine.)

• When the unit is plugged in the amber POWER light on the front panel should

illuminate

NOTE: For Lock Out / Tag Out plug the appropriate device into the line cord.

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Operator’s Manual: RS Series Chiller Chapter 2: Installation

High pressure Bypass Hook-Up (Accessory)

The high pressure bypass allows the user to control the pressure of the process fluid going to the application. This is particular can be useful if an application is sensitive to pressure such as a glass jacketed reaction vessel.

1) Thread Part 1 onto the process fluid output and tighten. The barb should face down. (remember to use pipe thread sealant on all metal to metal connections)

3) Take Part 3, remove the coupling and thread it onto Part 2 as shown, tighten.

2) Thread Part 2 onto the process fluid input and tighten. The opening should point toward left-hand side of the machine (operators left when looking at the control panel).

4) Pull the insulation on Part 3 back as shown. Tighten the coupling.

5) Slide the hose from Part 3 all the way onto the hose barb on Part 1. Position the hose clamp and tighten so that the hose is firmly gripped between the hose barb and the hose clamp.

Add Part 4, the insulation covers, to parts 1 and 2. Connect process fluid lines to Parts 1 and 2 as per the following instructions. Part 5 is the insulation cover for the T-Handle.

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Operator’s Manual: RS Series Chiller Chapter 2: Installation

Connect to the Process

FTS provides input and output connections for the process fluid. To tie these lines into your process, you will need:

•1/4” Fittings for 1/4” male pipe thread on the

Fluid I/O ports (3/8” Fittings for 3/8” male pipe thread on the Fluid I/O)

•3/8” ID tubing is recommended (1/2”ID

tubing for RS75)

•Pipe Insulation (Closed cell pipe insulation

will work for most applications. It can be purchased from any local refrigeration or plumbing supply house.)

•Glue seams of pipe insulation

•Teflon tape pipe sealant to seal all fittings

Always use caution when handling fluids, filling or draining the system reservoir, or working in or around the chiller. Always wear protective eyewear when operating the chiller.

Add Fluid

Once the fluid loop that runs to your application and back is in place and sealed, fluid can be added to the reservoir. The system can then be primed.

•Remove reservoir lid

•Fill reservoir to 1” (2.5cm) from the top and replace the lid.

•Press the I/O button (the pump will begin circulating fluid, if

more fluid is need to fully prime the process, immediately press the I/O button to stop the pump. Add more fluid, tighten lid and press the I/O button. Repeat this process of cycling the pump and adding fluid until the system is fully primed.

Your unit is now fully installed and ready to operate.

Page 14

System Preparation

•Plug the unit in if it is not already plugged in.

•System is now in Idle.

•Display will be blank and the amber Power light will

be illuminated

Start Up

•Press I/O button

•Display flashes SP (setpoint) then the current setpoint

temperature. (The setpoint is the temperature that the unit will maintain the fluid temperature at.)

•Adjust the Setpoint using the ▲▼ keys.

•Value for setpoint will be accepted after 4 seconds of inactivity.

Chapter

Operation

Control

•When the system is running touch the ▲ button to bring up the

setpoint.

•Adjust the setpoint using the ▲▼ keys.

•The setpoint is automatically accepted after 4 seconds.

Shut Down

•Press the I/O button to put the unit back in Idle.

•The refrigeration will shut down and the display will blank.

•The amber Power light will remain lit.

Page 15

Operator’s Manual: RS Series Chiller Chapter 3: Operation

NOTE: When changing setpoint, loosen the red vent screw

on the reservoir lid to accommodate for the expansion /

contraction of the process fluid. Once the chiller stabilizes

at a setpoint, tighten the red vent screw. This will help

prevent excess evaporation of the fluid, as well as

preventing atmospheric moisture from condensing on the

fluid.

High Pressure Bypass Adjustment

If using a High Pressure Bypass, take off the insulated valve cover. Use the brass THandle to adjust the operating pressure of the system to the desired levels.

Page 16

Chapter

UserMenu

This unit is equipped with an EDC digital control package. Varying the parameters in the EDC Controller’s User Menu allow the operation of the unit to be fine tuned to meet the needs of a specific application. A variety of parameters such as Ramp Rate, Auto-Power Recovery, High and Low Temperature Alarms, Parameter Lock, Setpoint Limits, readout options, Proportional Control parameters, and several Communications options can all be adjusted from the User Menus.

The layout of the menus and parameters contained in those menus is shown on the following pages. They are navigated using the three buttons on the front panel of the EDC Controller. The legends on the following pages show how to use these buttons to move around the menus and manipulate the values of the various parameters.

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Operator’s Manual: RS Series Chiller Chapter 4: User Menu

User Menu Layout

Operating Mode

(Unit is running or in IDLE)

Press & Hold

To view Menus

Choose Menu

Move down to

next parameter

Adjust

Parameter

Value

Pid

Proportional Control Menu

Ramp Rate

CPb

Cooling Band

HPb

(RS33 only-heat option)

Integral Time

Derivative Time

SPAn

Span Menu

High Alarm

Low Alarm

Span High

Span Low

Etc

Miscellaneous Menu

PLOC

Parameter Lock

Decimal Point

Power Fail Recovery

dEg

Temperature Scale

rdy

“Ready” Temp. Band

232

Communication Menu

baud

Baud Rate

Sbit

Stop Bit

dAtA

Word Length

PAr

Parity

Cct

Cool Cycle Time

Once a menu has been completed you are returned to the Operating Mode

rdyt

“Ready” Time Const.

Page 18

Operator’s Manual: RS Series Chiller Chapter 4: User Menu

Proportional Control Menu

I/O

Move to next

parameter

Adjust

Parameter

Value

Ramp Rate

CPb

Cooling Band

HPb

(RS33 onlyheat option)

Integral Time

Derivative Tim e

Programmed transition rate from old setpoint to new setpoint, in degrees per minute. Ramp Rate is more of a slew limiter, because the available ramp rate is obviously limited by the thermal load and the pulldown capacities of the refrigeration system.

Width of the temperature span across which cooling is proportionately applied to the process, in degrees. Note: this is band centered on the setpoint, so a CPb of 5 degrees defines a window that’s +/- 2.5 degrees from the setpoint.

Width of the temperature span across which heat is proportionately applied to the process, in degrees. In a heat-only mode this would equate to +/- 2 degrees from setpoint. In this system (heat/cool operation) the band is offset below setpoint and then further shifted up or down by the Deadband/overlap parameter.

Integral (Automatic Reset) time, in seconds. Time constant for adjustment of proportioning action that serves to correct deviations from setpoint.

Derivative (Rate of Change adjustment) time, in seconds. Time constant for adjustment of proportioning action in order to reduce the slew rate of the process as it approaches the setpoint. Derivative time is automatically limited to 1/4 of the Integral Time (It).

Cct

Cool Cycle Time

Period of operation of the cool/bypass refrigeration valves, in seconds. In order to reduce wear on the solenoids and valves, the period (total time on and off) may never be less than two seconds. Additionally, the duration of either On or Off is never less than 0.25 seconds.

Page 19

Operator’s Manual: RS Series Chiller Chapter 4: User Menu

Span Menu

An alarm can be set to alert the user that the process temperature is too high. Should the HA be triggered, the system will go to FULL COOL and the display will flash HA. The temperature alarms are monitored even if the system is in IDLE, in case the user turns off the system without removing the load; in such an instance, however, the unit is incapable of supplying full cool, and it is the responsibility of the user to correct the anomaly.

I/O

High Alarm

Parameter

Adjust

Parameter

Value

Low Alarm

Span High

Span Low

Same as HA, except the system will stop all refrigeration and display LA Both HA and LA require user reset; clear the messages by pressing the ∇ key. They will not disappear even if the process returns to the correct level.

SH defines the maximum allowable setpoint. Adjust the values of Span High and Span Low to define the range of setpoints acceptable for your particular application.

SL defines the minimum setpoint in this range.

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Operator’s Manual: RS Series Chiller Chapter 4: User Menu

Miscellaneous Menu

I/O

Parameter

Adjust

Parameter

Value

PLOC

Parameter Lock

Decimal Point

Power Fail Recovery

dEg

Temperature Scale

rdy

“Ready” Temp. Band

rdyt

“Ready” Time Const.

If set to 1, operating parameters may not be changed unless system is off (not running). Note that if this is set while the unit is running, it may not be reset unless the system is first turned off.

If set to 1, decimals will be displayed. If set to 0, readout will be in integer format. NOTE: Residual decimals will be carried internally. Therefore, before using integer format, the SP should be corrected to xx.0 prior to suppressing the decimal point.

The power failure recovery setting determines what the controller will do following a power failure. If set to 1 the controller will automatically restart the system if it was running when power was lost. The display will show “PF” to indicate that there was a power failure. (Clear PF message by pressing the ∇ key) If set to 0 the Auto-Recovery function is shut OFF.

For Celsius set: 0 For Fahrenheit set: 1 For Kelvin set: 2

The temperature band about SP, in degrees, by which the system may be defined as "ready". The "ready" value (0/1) is normally available via a query to the chiller via the RS-232. Note that this is a "band". The default value of 5.0 thus equates to +/- 2.5 degrees from SP. The Ready Temperature operates in conjunction with the Ready Time described by the next parameter.

A time constant, in seconds, which the software uses to determine the "ready" condition. The process temperature is continuously integrated across a period of time defined by this constant to ensure that stability has been achieved.

Page 21

Operator’s Manual: RS Series Chiller Chapter 4: User Menu

Communications Menu

Baud Rate for the RS-232 control communications port may be set according to the table.

I/O

Parameter

baud

Baud Rate

Sbit

Stop Bit

Display Baud 0 300 1 1200 2 2400 3 9600

The number of stop bits (1, 1.5, 2) may be selected

Adjust

Parameter

Value

dAtA

Word Length

PAr

Parity

Data word length may be set to 7 bit or 8 bit

Parity detection may be selected per the following:

Display Parity 0 none 1 odd 2 even

Note: Data word 8 bit length forces “no parity.”

Page 22

Operator’s Manual: RS Series Chiller Chapter 4: User Menu

High Fluid Temperature

How Reported:

Description:

How Detected:

Appropriate

Response:

The display will flash HA, and the system will go to FULL COOL.

Indicates that the temperature of the process fluid going to the equipment is higher than the level set (HA) to trigger the high fluid temperature alarm. This is a user feature that can be adjusted to the desired temperature by altering the value for HA in the SPAN menu. If the thermal load is greater than the chiller’s heat removal capacity, the unit will not be able to hold the setpoint temperature. This situation is potentially damaging to equipment, so set the HA just above the setpoint temperature so that you are alerted of temperature runaways before they damage equipment.

A thermocouple monitors the temperature of the fluid leaving the chiller.

Check the setting of the high temperature alarm (HA) by pressing and holding the Δ button while the system is in idle, to get into program mode. Then using the Δ and ∇ keys find the SPAn menu, press I/0 button until HA is displayed, note the temperature for HA. Press I/0 button until you exit the menu, Start system to show the current setpoint. Then either decrease the temperature setpoint to ensure it is set below the high temperature alarm setting (HA), or adjust the HA value so that it is above the desired setpoint. If the HA still goes off, check that the thermal load being applied by your process is within the heat removal capacity of this unit. Contact the FTS Service Division if the condition persists.

Page 23

Operator’s Manual: RS Series Chiller Chapter 4: User Menu

Low Fluid Temperature

How Reported:

Description:

How Detected:

Appropriate

Response:

The display will flash LA, and the system will go to full bypass.

Indicates that the temperature of the process fluid going to the equipment is lower than the level set for the low fluid temperature alarm (LA). The user can set the temperature that this alarm will be triggered by altering the value for LA in the SPAN menu.

A thermocouple monitors the temperature of the fluid leaving the chiller.

Check the setting of the low temperature alarm (LA) by pressing and holding the Δ button while the system is in idle, to get into program mode. Then using the Δ and ∇ keys find the SPAn menu, press I/0 button until LA is displayed, note the temperature for LA. Press I/0 button until you exit the menu. Start system to show the current setpoint. Then either increase the temperature setpoint to ensure it is set above the low temperature alarm setting (LA), or adjust the LA value so that it is lower than the desired setpoint. Contact the FTS Service Division if the condition persists.

Page 24

Operator’s Manual: RS Series Chiller Chapter 4: User Menu

PID Tuning

Since each installation has different conditions of operation (ambient temperature, water temperature, different fluid loop length, etc), the factory PID settings do not always provide optimum control at the required temperature setpoint.

Press & Hold

To view Menus

Choose PID

I/O

displayed value

and move to

next parameter

Adjust

Parameter

Value

Use the instructions outlined below to view and adjust the PID settings.

To get to the menus press and hold the Up Δ or Down ∇ button. Once in Program Mode use the Up Δ and Down ∇ buttons to move between menu headings. When PId is displayed, press I / O. Once inside a menu, use the Up Δ and Down ∇ buttons to adjust the value of parameters. The I / O button accepts the value displayed and steps down to the next parameter in the menu.

After the last parameter has been stepped through, you are returned to the Operational Mode.

The following pages contain the basics of how to go from the values at right and tune the unit for your specific application. In most cases it is sufficient to just calculate a new Integral Time (It) and enter that into the controller.

Page 25

Operator’s Manual: RS Series Chiller Chapter 4: User Menu

IT and DT

Measure the period of the temperature oscillations, peak temperature to peak temperature.

time(t)

It Time Integral

≤=

dt Time Derivative

NOTE: This represents the maximum value for derivative time. It can be lowered.

Temp

Program the results into the controller using the instructions outlined in PID Tuning.

Time (t)

Time

CCT

To determine the Cool Cycle Time (CCt), run the unit at the temperature that you wish the unit to control best at. The temperature will probably oscillate as the controller attempts to maintain temperature at the setpoint.

Watch the Cool Light Start a stopwatch when the Cool light comes on, wait for the light to go off, and stop the stopwatch when the temperature begins to rise again. Using the instructions on PID Tuning, set the the value of CCt = time on the stopwatch (in seconds).

Setpoint

Example:

Temp

Cool LED ON

Cool LED OFF

Time

Time (t)

Setpoint

Rise in

Page 26

Operator’s Manual: RS Series Chiller Chapter 4: User Menu

=+=

CPB

Note the amount the temperature swings above and below the setpoint. The temperature swing is used to figure the proportioning band.

Cool Proportioning Band CPb = Temperature swing below setpoint + 10% of that temperature swing

Example:

(CPb)

Temp

20°C

21°C

1°C above

setpoint

°+°=

Program the results into the controller using the instructions outlined in PID Tuning. NOTE: New values for CPb are only processed with a new setpoint. Therefore after

entering a new value for CPb, it is necessary to get out of the Program Mode (successive I /O’s) and change the setpoint. Once in the Operation Mode, change the setpoint (press the Up Δ key twice and then I / O), then you can change it back (press the Down ∇ key twice, and press ENTER). The new value for CPb will now be used.

2°C below

setpoint

Time

1.1 0.1 1 C1 of 10% C1 CPb

18°C

Setpoint

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=+=

HPB, CPB, AND DB

Note the amount the temperature swings above and below the setpoint. These temperature swings are used to figure the proportioning bands and the dead band. Heat Proportioning Band HPb = Temperature swing above setpoint + 10% of that temperature swing Cool Proportioning Band CPb = Temperature swing below setpoint + 10% of that temperature swing Dead Band db = HPb or CPb (whichever is lower) divided by 2 and then rounded down. Take the result and make it negative.

(db)

(RS33 – Heat option only)

(HPb)

(CPb)

Example:

Temp

20°C

21°C

1°C above

setpoint

2°C below

setpoint

18°C

Time

°+°=

C1.1

()

−=

1.1 0.1 1 C1 of 10% C1 HPb

2.2 0.2 2 C2 of 10% C2 CPb

=+=°+°=

0.5 down rounded C55.0

−=°−=

Setpoint

NOTE: New values for HPb, CPb, and db are only processed with a new setpoint. Therefore after entering new values for HPb, CPb, and db it is necessary to get out of the Program Mode (press ESC) and change the setpoint. Once in the Operation Mode, change the setpoint (press the Up Δ key twice and then ENTER), then you can change it back (press the Down ∇ key twice, and press ENTER). The new values will now be used.

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Chapter

RS‐232Communications

ProgrammerʹsReference

OVERVIEW

The MPC and EDC controllers are used in a variety of cooling products manufactured by FTS. The commands used by a specific system will vary per the descriptions at the end of this reference, but the operational aspects, hardware and software, of the interface are consistent across the product line. This document details the communications interface between the microcontroller and the [independent] intelligent host processor.

At the end of this chapter is a sample program which will execute on an IBM-compatible PC within either GWBASIC or QBASIC. It is suggested, should initial attempts to communicate be unsuccessful, that this program be tried. It is as unencumbered as a program may be and will aid in locating the source of difficulty: if this program runs successfully, then the difficulty must be due to one of the “extras” or “features” of the unsuccessful driver.

HARDWARE

The hardware of the RS-232 interface meets or exceeds the specifications of EIA standard RS-232-E-1991, with regard to electrical characteristics (impedance, open-circuit characteristics, voltages, etc.).

The physical interface connector is a 9-position female D-subminiature connector, with pin-out as specified by the IBM Corporation for the "PC-AT" [COM1] communication port.

The connections used within the interface will be limited to:

GND Signal Ground TXD Transmit Data RXD Receive Data

All other signals of the RS-232 standard are immaterial to this application, or terminated, as appropriate.

Communications

Communication operates at a user-definable BAUD rate selectable from 300, 1200, 2400, 9600.

Parity may be odd, even, or none. The interface uses one Start bit and either one, one-and-a-half, or two Stop bits (user-selectable).

Data word length is selectable at 7-bit data with designated parity, or 8-bit data without parity. All data in both directions is transmitted in ASCII.

Selections of BAUD rate, parity, and stop bits are made to the microcontroller via the control panel of the target (application) system.



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COMMUNICATION DATA

All programmable, selectable, or switchable functions of the target system are accessible via the RS-232, with the exception of the RS-232 configuration itself, which may not be programmed from the host.

All data, programmed values, status, and system errors are accessible by the host, i.e., an appropriate query by the host will result in a data stream returned from the system as defined below.

DATA FORMAT

All data is transmitted in ASCII. All data values are transmitted via decimal character strings. Upper and lower case alphabetic characters will be accepted interchangeably. Data descriptions are identified by direction from the perspective of the system controller:

Received (from the host system to the MPC/EDC) and Transmitted (from the MPC/EDC to the host) data.

RECEIVED DATA

Data may be transmitted at any time by the host. Status queries will be answered whether or not the unit is in local or remote. Any change in system status (except "Goto Remote") requested via the RS-232, however, will require that the unit be in the "remote" state; otherwise an error will be reported to the host.

Data uses a "line" format, consisting of the following:

CMD <opt CMD> <opt CMD> <...> CR <opt LF>

where: CMD is any valid transmitted data string CR is an ASCII "Carriage Return" LF is an ASCII "Line Feed"

Data commands may be grouped within a "line" command, or transmitted singly. A data string must be terminated by a "Carriage Return" (ASCII 013 decimal / 0D hex). "Line Feed" (ASCII 010 decimal / 0A hex) may be optionally inserted by the host, but will be ignored. A "line" may not exceed 128 characters.

A listing and description of the available CMD statements appears in a later section.

Data commands which are grouped on a line must be separated by a single "Space" (ASCII 032 decimal / 20 hex).

The Delete/Rubout character (ASCII 127 decimal / 7F hex) will NOT be recognized. Unrecognized characters will result in an error acknowledge.

ANY error in transmission/reception of a "line" will assume corruption of the ENTIRE line, and ALL commands in that line will be ignored. This includes not only transmission (e.g., parity) errors, but values out-of-bounds, undefined commands, etc. This ensures that state changes are not presented to the system (e.g., new Setpoint SP) without all corresponding desired changes (such as corresponding PID values).

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All data received by the target system will be presented by the host system as a character string of one of the following formats:

1) Absolute Command

Basic system functions/commands will consist of a fixed character string.

Examples:

"START" -- Wake up system "STOP" -- Shut down system "POLL" -- Force a response from the system

2) Parametric Command

A parametric command describes a function/command for which a value must be specified. The command characters must be followed by an "equals sign" ("=") (ASCII 061 decimal / 3D hex), and a data string of decimal value.

The value may optionally contain a decimal point (except where required to define decimal fractions). Negative values require a "minus sign" ("-", ASCII 045 decimal / 2D hex) between the "equals sign" and the value. A plus sign ("+") may be used, but is not required.

Each programmable value within the system is assigned a set of limits by the system. Certain of these limits may be further modified by other program commands. Values which exceed the boundaries of either of these limits will result in an error.

The number of characters attached to the "value" field may not exceed eight; an error will result accordingly. Leading zeroes, or trailing zeroes behind a decimal point, may be added without effect, up to the character limit.

Examples: SP=20 ;Adjust Setpoint to 20 degrees SP=+20. ;Adjust Setpoint to 20 degrees SP=020.00 ;Adjust Setpoint to 20 degrees SP=-60.3 ;Adjust Setpoint to -60.3 degrees CPB=3.6 ;Adjust Cooling Proportioning Band to 3.6 degrees

Controllable features which are not system "program parameters", such as switches, use the values "0" to represent "off" and "-1" to represent "on" (byte false = $00 = 0, byte true = $FF =

-1).

Examples: PUMPSW=-1 ;Turn pump switch on PUMPSW=0 ;Turn pump switch off

3) Query Command (request for information)

A request for information from the MPC to the host is an absolute command. However, all commands which expect data in reply to the command end with a question mark ("?"). The format of the reply is defined below (under "Transmitted Data"). With few exceptions, the query command replicates the mnemonic for the corresponding parametric command, merely substituting the "?" for the "=" in the string.

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TRANSMITTED DATA

It is anticipated that in a remote-controlled operation of the target system, the actual controlling "device" may be either a computer with a software program, or a human being working interactively. The format of returned data has been optimized for evaluation by a computer program, although it can be intelligently read by a human working in an interactive mode.

The content of transmitted data to the host is dependent upon the type of received data to which the system is answering. The returned message consists of one or more segments:

a) Acknowledge: receipt and acceptance of a message which is syntactically correct, meets all constraints or limits imposed by the system, and which has been subsequently processed, is acknowledged by the character string "OK".

Exception: certain absolute commands may result in a “runtime” error (in other words, will result in an error when the software attempts to actually execute the statement). These will result in both “OK” and the error message described below.

b) Error Message: receipt of a message which is syntactically incorrect, exceeds system limits, or is otherwise faulty (such as Parity Error), will result alternately in an error message.

c) Parameter Message: in response to a query, the parameter and its value will be returned to the host. If multiple value/status queries are transmitted in a single statement, the multiple replies will be transmitted on multiple lines (i.e., separated by carriage returns).

d) Terminator Character: All messages will be terminated by an exclamation point ("!") (ASCII 033 decimal / 21 hex). This character is appended to a single-line message, including "OK", or to the end of the last line of a multiline message if the host has transmitted queries.

The controller is capable of "full-duplex" operation; i.e., it is capable of receiving data while transmitting data. However, it is strongly suggested that the host wait for the message

and the exclamation point ("!") before proceeding to its next transmission, to ensure correlation between information sent and the replies.

The Command POLL has been provided as a non-operative command (similar to an assembly-language NOP or BASIC-language REM) to verify establishment of communications between the host and the slave. The POLL command will have no effect on the state of the controller or its system, and can result in an error only if the RS-232 connection itself is not correct (e.g., wrong BAUD rate, parity error, etc.).

Once the POLL command has been issued, and the string "OK!" has been received by the host, the software may be assumed to be synchronized. User software should be configured to transmit a message (received data), receive the reply (transmitted data), and verify the integrity of the exchange before proceeding to the next transmission.

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TRANSMITTED DATA FORMAT ACKNOWLEDGE

The explicit characters "OK" acknowledge receipt of a valid message, followed by 11 spaces (not counting the space for line continuation, described below).

ERROR

The line begins with the character "E", followed by a 3-digit decimal value defining the error number. It is up to the user to provide necessary messages defining the error, if desired. A full listing and description of error numbers is provided in a later section of this document.

An "equals sign" ("=") follows, and is then followed by a "plus" ("+") and 7-digit explanation code. For character-traceable errors, the number indicates the column position of the character which resulted in the error. Positions are numbered 0-127, 0 representing the first character and 127 the last permissible character. If the error is due to a general error (e.g., "LINE TOO LONG"), the character-trace code is 128.

Example A:

Received string: START

Transmitted string: E030=+0000128!<CR>

(Error 30 = "Unit Not in Remote")

Example B:

Received string: SP=25 CPB=2.5 IT=35,0 DT=6

Transmitted message: E021=+0000019!<CR>

(Error 21, Illegal character, in position 19)

VALUE

The line begins with the character "F" (Function), followed by a 3-digit decimal code defining the opcode number assigned to the parameter. Following the function code is an "equals sign" and an 8-character value. This value will ALWAYS begin with a polarity sign ("+" or "-"), followed by either a) 7 digits; or b) 6 digits with an embedded decimal point.

The value 0 will always be "positive".

All temperatures are internally resolved to 0.01 degrees F. Temperature values will always be returned with full resolution on the RS-232 regardless of the resolution of the control panel display or the user display options. Temperature values will be transmitted to the host in the units (C, F, K scale) selected by the DEGREES= command (or via the dEG setting in the control panel “Etc” menu).

Values for system characteristics which are not programmable parameters: e.g.: switches, on/off status, etc., will be returned as byte status. In other words, if the state is "true", the returned value will be +0000255 (byte true hex FF); if the queried status is false, or off, the returned value will be +0000000 (byte false hex 00).

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Example:

Received string: SP?

Transmitted message: OK <CR> F057=-0030.00!<CR>

(Function #57, Setpoint, is currently -30 degrees)

TERMINATOR

The exclamation point ("!") is issued prior to the last <CR> to indicate "end of message", so that multiline messages may be accommodated. To facilitate message parsing by column position, this position is left with a "space" if the line is not the last of the message.

COMMAND SET

The following commands are defined to the interface. Certain commands, while syntactically acceptable to the parser, will result in the error code "Not Yet Implemented" (nyi); these have been defined for future expansion or options. The command opcode (function "F" number) which will be returned by a query appears in curly-brackets following each query command. Upper case is used to note other [referenced] commands.

ALARMH= / ALARMH? {F001}

Set or query the user setting of the overtemperature (high) alarm condition, in degrees. Limits are imposed by FLUID= and the factory-set system span (SSPANH).

ALARML= / ALARML? {F002}

Set or query the user setting of the undertemperature (low) alarm condition, in degrees. Limits are imposed by FLUID= and the factory-set system span (SSPANL).

ALMCODE? {F076}

Query the status of the system alarm table. A reply of 0 indicates a no-alarm condition. Other codes are documented in a separate section, below.

BAUD? {F003}

Report the present BAUD rate in use in the communication link. Values returned will be the same as those programmed via the system control panel: 0=300, 1=1200, 2=2400, 3=9600.

CASC? (Service Use) {F004}

Report the existence of a two-stage refrigeration system (0=single compressor, 1=cascade).

CBLI? (Service Use) {F005}

Report the configuration of cool/bypass/liquid injection valves in a given system configuration.

CCT= / CCT? {F006}

Set or query the Cool Cycle Time: the on/off period assigned to the proportioning cooling valves, in seconds.

CH= / CH? (Not Yet Implemented) {F007}

Define steering of loop-dependent commands to ch.1 or ch.2 in a dual-loop system.

CLOCK= / CLOCK? (Not Yet Implemented) {F008}

Define or query the existence of Real Time Clock hardware.

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CLRALARM

Clear alarm conditions from the system, if any exist. Restore ALMCODE? to 0. If the condition creating the alarm state persists, however, the system will restore the alarm until that condition is corrected.

CPB= / CPB? {F010}

Set or query the width, in degrees, of the band about setpoint (SP) over which the control system will proportion the cooling valves (Cool Proportioning Band).

CTLREM= / CTLREM? {F011}

Set or query the use of the remote sensor for temperature control of the system. Value 0 (off) means "control from the internal sensor"; 1 (on) means "control from the remote sensor". If the remote sensor is not connected (open circuit), the system will automatically revert to internalsensor control and an alarm will result.

CURRSNS? (Service Use) {F012}

Query the existence of pump/compressor current sensors as defined by the system hardware complement (factory set). 0 = off/don't exist; 1 = on.

DATE= / DATE? (Not Yet Implemented) {F013}

Set or query date in Real Time Clock option.

DB= / DB? {F014}

Set or query the deadband, in degrees, between the heat and cool proportioning bands (HPB/CPB). This value is usually negative, implying overlap.

DEFAULT (Not Yet Implemented)

Restore factory default values to the programmable parameter table.

DEGREES= / DEGREES? {F016}

Set or query the temperature scale used on the display and in further RS-232 communications. 0 = Celsius, 1 = Fahrenheit, 2 = Kelvin.

DP= / DP? {F017}

Set or query the use of integer/decimal format on the control panel display. 0 (decimal point off) displays temperature rounded to the nearest integer; 1 (decimal point on) displays temperature with 0.1 resolution.

DT= / DT? {F018}

Set or query, in seconds, the [derivative] time constant applied to the proportioning band adjustment, as a function of rate of change in the process temperature.

FLUID= / FLUID? {F019}

Set or query the number defining the fluid type in use in the system (see system programming documentation for a listing). Fluid definition automatically sets FSPANH and FSPANL, subject to SSPANH and SSPANL, to limit the permissible bounds of the setpoint SP and the alarm temperatures ALARMH and ALARML.

FORMAT= / FORMAT? (Not implemented / obsolete) {F020}

Describes the format of transmitted data. Task offloaded to the host processor.

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FSPANH? {F021}

Query the high temperature limit (degrees) established by the FLUID definition.

FSPANL? {F022}

Query the low temperature limit (degrees) established by the FLUID definition. GNREM= / GNREM? {F023} Adjust or query the calibration gain factor applied to the remote [external] temperature sensor.

GNRTD= / GNRTD? {F024}

Adjust or query the calibration gain factor applied to the system [internal] temperature sensor.

HEATER? (Service Use) {F025}

Query the system heater configuration and phase connection definition.

HLPC? (Service Use) {F026}

Query the existence of high-low-pressure cutout on the system compressor(s). Used in watercooled units. 0 = not used, 1 = exists.

HPB= / HPB? {F027}

Set or query the width, in degrees, of the band about setpoint (SP) over which the system will proportion the power applied to the heater (Heat Proportioning Band).

HYSTLI? (Service Use) {F028}

Query the hysteresis, in degrees, applied to activation of the liquid injection valve.

HYSTST2? (Service Use) {F029}

Query the hysteresis, in degrees, applied to measurement of the cascade condenser (first refrigeration stage output), for operation of the second-stage refrigeration.

IT= / IT? {F030}

Set or query the [integral] time constant, in seconds, applied to the adjustment of the proportioning band, governing the automatic reset ("droop" correction) of the process temperature to setpoint. Note: the IT value is applied only to the internal temperature-control sensor. If the remote sensor is in use (CTLREM=1), the command ITREM should be used. The proper selection of IT or ITREM is automatically performed by the system software per the CTLREM command.

ITREM= / ITREM? {F031}

LOCK= / LOCK? {F032}

Set or query the state of the Local / Remote lockout. If set to 0, the LOCREM= command may be asserted. If set to 1, the LOCREM= command will result in an error message.

LOCREM= / LOCREM? {F033}

Set or query the local / remote control status of the system. If set to 0, the system may only be programmed from the [local] control panel. If set to -1, the system may only be programmed from the remote communication link. If the system is in local control (LOCREM=0), all commands AAAAAAAA=, except the LOCREM= command, will result in the error message "unit is in local". Queries will perform normally. If LOCK=1 the LOCREM= message will return the error message "unit is locked in local/remote".

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LOOP2? (Service Use) (Not Yet Implemented) {F034}

Query existence of a second control loop, in dual-loop systems.

MODE? {F035}

Query the control configuration of the system (factory-set per configuration). 0 = heat and cool, 1 = cool only, 2 = heat only.

NOISE= / NOISE? {F036}

Set or query the action of the audible alarm (activated under fault conditions in conjunction with the red alarm lamp on the control panel). 0 = "off", 1 = intermittent "chirp", 2 = continuous "on".

OSREM= / OSREM? {F037}

Set or query the calibration offset factor applied to the remote [external] temperature sensor.

OSRTD= / OSRTD? {F038}

Set or query the calibration offset factor applied to the system [internal] temperature sensor.

PARITY? {F039}

Query the parity setting of the communication link. 0 = no parity, 1 = odd, 2 = even.

PF= / PF? {F040}

Set or query the selection of the automatic power recovery algorithm. 0 = disabled, 1 = enabled.

PLOCK= / PLOCK? {F041}

Set or query the status of the parameter lockout feature of the control panel. If set to 1, menu values may not be changed from the control panel while the system is running, even if the unit is in "local" operation. If set to 0, the system may be fully programmed from the control panel at any time if the unit is in "local". If PLOCK has been set to 1, system operating parameters may only be changed from the control panel if the unit is first turned off (STOP).

POLL

A non-operative command which may be used to test or synchronize the communications interface.

PT? {F043}

Query the current process temperature (as defined by the control point CTLREM).

PTLOC? {F044}

Query the current local process temperature (per the internal sensor).

PTREM? {F045}

Query the current remote process temperature (per the remote sensor).

PUMP? {F046}

Query the status of the circulating pump. 0 = off, -1 = on.

PUMPSW= / PUMPSW? {F047}

Set or query the state of the pump switch. 0 = (turn) off, -1 = (turn) on.

RAMZERO (Not Yet Implemented)

Command to zero out the microprocessor memory for restart of a "dead" unit.

READY? {F077}

Query state of process ready-determination stability algorithm (0 = not ready/stable, 1= ready/stable) per program values SP, WINDOW, and WINTIME.

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REFR? {F050}

Query state of refrigeration. Returned 0 = off, 1 = 1st stage on, 2 = 2nd stage on (if cascade system).

REFRHRS? {F078}

Query running hours of system refrigeration.

REFRSW= / REFRSW? {F051}

Set or query state of refrigeration switch. 0 = off, -1 = on.

REV? {F052}

Query [embedded] software revision level in system program ROM.

RFC

Command to restore factory-determined calibration constants.

RR= / RR? {F054}

Set or query setpoint transition rate (Ramp Rate), in degrees per second.

STOPBITS? {F055}

Query the programmed number of Stop bits in the RS-232 communication definition. Values may be 1, 1.5, or 2.

SP= / SP? {F057}

Query or set the system temperature setpoint, in degrees.

SSPANH? {F058}

Query the factory-set maximum allowable setpoint, in degrees (determined by system hardware complement).

SSPANL? {F059}

Query the factory-set minimum allowable setpoint, in degrees (determined by system hardware complement).

START / START? {F060}

Command to turn the system on (subject to positions of PUMPSW and REFRSW) and to initiate the system temperature control software. Query to determine whether the system is running ( 0 = off, -1 = on ).

STATUS? (Not implemented, obsolete). STOP

Command to turn the system off, restore displays and controls to idle.

SYSHOURS? {F063}

Query number of running hours accumulated on the system, as determined by the number of running hours on the pump.

TEMPLI? (Service use) {F064}

Query temperature, in degrees, of suction line, for control of liquid-injection valve in refrigeration hardware.

TEMPST1? (Service use) {F065}

Query temperature, in degrees, of the cascade condenser (heat-exchanger output of the first refrigeration stage in a two-stage system).

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TIME= / TIME? (Not yet implemented) {F066}

Set or query time of day in Real-Time Clock option.

TRIPLI? (Service use) {F067}

Query factory-programmed trip temperature of suction line, to determine operation of the liquid injection valve.

TRIPST2? (Service use) {F068}

Query trip temperature, in degrees, of cascade condenser, for turn-on of the second stage refrigeration.

UPHOURS? {F069}

Query total hours of system operation (including off), from engagement of Emergency Off switch. USPANH= / USPANH? {F079} Set or query SP upper operating limit, in degrees, as determined by the user's requirement. This limit may not exceed the value FSPANH? or SSPANH?

USPANL= / USPANL? {F080}

Set or query SP lower operating limit, in degrees, as determined by the user's requirement. This limit may not be more negative than the value FSPANL? or SSPANL?

WAKE= / WAKE? (Not Yet Implemented) {F070}

Set or query the status of the automatic-wakeup function.

WAKEMINS= / WAKEMINS? (Not Yet Implemented) {F071}

Set or query the elapsed time to automatic wakeup.

WAKETIME= / WAKETIME? (Not Yet Implemented) {F072}

Set or query the automatic-wakeup time set via Real-Time Clock option.

WINDOW= / WINDOW? {F073}

Set or query the window, in degrees, used to determine process stability (conformance to setpoint), as reported by the system "Alarm/Ready" contacts.

WINTIME= / WINTIME? {F074}

Set or query the time constant, in seconds, used to determine process stability (conformance to setpoint), as reported by the system "Alarm/Ready" contacts. This time is a time constant used in the stability integration and determination algorithm, not an absolute time value. Small movements in process temperature will be determined to be stable more rapidly than large swings. This value is used to prevent over/undershoot of the setpoint temperature from yielding a premature "ready" result.

ZEROCAL (Not Yet Implemented)

Command to restore all calibration constants to the unbiased state (zero offset, unity gain).

ALARM CODES

Numeric codes are returned to the query ALMCODE? per the following alarm conditions. Alarms, once set, are maintained until explicitly cleared, even if the alarm condition has been corrected.

MPC/EDC Code 0: No outstanding alarm condition. MPC/EDC Code 1: Low fluid level in system. MPC/EDC Code 2: Low fluid flow in system (inadequate pressure in return line).

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MPC Code 3: EDC Code 6: Insufficient cooling water in water-cooled system.

MPC Code 4: Stage 1 Refrigeration is not powered, as determined by current sensors. This

failure can be due to [internal] overtemp cutouts, trip of a circuit breaker, etc.

MPC Code 5: Stage 2 Refrigeration is not powered. See Code 4. MPC Code 6: Pump is not powered. May be not powered, fuse may be blown, etc. MPC Code 7: System has been programmed for control from Remote sensor. Remote sensor

is open-circuit.

MPC Code 8: EDC Code 3: High temperature alarm. Process temperature exceeds ALARMH?

MPC Code 9: EDC Code 4: Low temperature alarm. Process temperature has fallen below ALARML?

MPC Code 10: Same as MPC Code 4, for a single-stage (only one compressor) system. MPC Code 11:

EDC Code 5: Overtemp. Indicates activation of fail-safe [control-independent] overtemperature

safety device. MPC Code 12: 4-20mA Alarm. Indicates disconnect of 4-20mA current source to remote analog

programming input, if such interface is specified.

RS-232 ERROR CODES

The following error codes are returned Ennn if the parser/syntaxer/limits-checking software finds fault with the received string.

Group 0: UART Transmit/Receive and General Receive errors. E001 UART Overrun. Character received by UART before previous character has been

retrieved from the character input buffer. Microprocessor hardware failure. E002 Parity Error. Character detected has incorrect parity as defined by control-panel

programming. See PARITY? E003 Frame Error. Incorrect number of Stop Bits detected on received character. See

STOPBITS? E004 Break Error. UART detects loss of RS-232 line with host. This error is only reported if

such a break occurs after the receipt of valid data, and before receipt of a <CR> (carriage return). Line break is otherwise ignored.

E005 Line Too Long. Received "line" (character string) exceeds 128 characters without receipt of <CR> (carriage return).

E006 Receive Buffer Ov errun. 1KB character input buffer is full. Commands are being received faster than they can be processed.

E007 Line Buffer Overrun. Lines are being received faster than they can be processed.

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E008 Break Error. See E004. Group 1 Errors: General Parsing and Transmission Errors E010 Transmit Buffer Overflow. Requests for information (queries) result in information

being buffered faster than it can be transmitted to the host (Baud-Rate dependent). 1KB buffer exceeded.

E011 Parse Buffer Overflow. Too many commands (>32) on a single line.

Group 2 Errors: Command Parsing Errors E020 Undefined String. Character string not identified as valid command, in position

indicated by trailing argument. E021 Illegal Character. Character in string not a recognized character (A-Z, a-z, 0-9, "=", "?",

".", "+", "-", <SP> (space), <LF> (line feed), or <CR> (carriage return). E022 Illegal Operand. Keyword string followed by illegal operation (command, program,

query). E.g., TEMPST1 may only be queried; is a temperature which exists in the system and is measured. Attempt to program via TEMPST1= will yield E022.

E023 Question Mark (?) Follo wed by Argument. Query will not accept an argument. E024 Value Too Long. Programmed value may not exceed 8 characters. E025 Illegal Sign Placement or Excess Decimal Points. Polarity indication (+,-) must be first

character. Only one decimal point permitted per number.

E026 Too Many Decimal Places. Too many digits supplied after decimal point. E027 Value Out of Bounds. Programmed number exceeds limits fixed internally or by

superseding limits (e.g., FSPANH will limit USPANH). E028 Excessive number. The previous filters will allow certain [illegal] ranges of numeric

possibility to get through. This error traps these ranges before they cause software mathematics errors (due to register overflow, etc.).

Group 3 Errors: Security Errors E030 Unit Not in Remote. Attempt has been made to program a value which may not be

altered if system is presently switched to "local" operation. E031 Not a User Function. Certain program statements are reserved for factory access.

Error 31 reports an attempt to program values requiring [factory] security-code access.

Group 4: Operational and Miscellaneous Errors E040 Not Yet Implemented. Use of a command which is defined to the parser but not

presently implemented by FTS. E041 Stop Error. System already stopped has received a "STOP" command.

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Operator’s Manual: RS Series Chiller Chapter 5: RS232 Communications

E042 Start Error. System already started has received a "START" command. E043 Not a User Function. Certain operational commands are defined to the system and

reserved for factory use. Error 43 reports use of such a command without proper security access.

E044 Local Lockout. Unit is locked in local. Removal of this lock may only be accomplished from the system control panel before changes to system state may be made from the RS-232.

SAMPLE PROGRAM

The following program is supplied to assist in troubleshooting should the user’s attempts to communicate via the RS-232 be unsuccessful. It will execute properly from either GWBASIC or QBASIC on an IBM-compatible PC. If this program runs, the alternate driver has a software or configuration problem. If this program does not run properly, a hardware problem (usually a miswire) is indicated.

This program was designed to be as simple as possible. It therefore performs no syntax checking or error detection. It will prompt “COMMAND?”, to which the user should type the string desired to send (e.g., “SP?<CR>”). The character string returned by the MPC will be displayed on the user’s terminal. Users will note that the transmit/receive strings appear to be “out of synch” on the terminal display; this is also to keep the program as short and unencumbered as possible.

The Rubout, Backspace, and Delete keys will NOT work. They will be transmitted like any other character (and will result in an error message “Illegal Character”).

Once the program has been typed into BASIC (or loaded from disk), it may be run from GWBASIC by typing “RUN”, or from QBASIC from ALT-R-S or Shift-F5. To stop the program, use CTL-BREAK.

5 OLINE$="" 10 OPEN "COM1:9600,N,7,1,RS" AS #1 20 PRINT "COMMAND: "; 30 A$=INKEY$ 40 IF A$="" THEN GOTO 110 50 PRINT A$; 60 OLINE$=OLINE$+A$ 70 IF A$ <> CHR$(13) THEN GOTO 30 80 PRINT #1,OLINE$; 90 OLINE$="" 100 GOTO 20 110 WHILE NOT EOF(1) 120 B$=INPUT$(LOC(1),#1) 130 PRINT B$; 140 WEND 150 GOTO 30

Page 42

Chapter

Maintenance

Warning! Hazardous voltages. Risk of electric shock. Disconnect all power before servicing this unit. Refer servicing to qualified service personnel.

Caution! Power supply phases to this unit must be in correct sequence

Notice! Only qualified personnel should perform maintenance on the

refrigeration system itself, and only EPA certified technicians may evacuate or charge refrigerants.

Hazardous Material/Contact Hazard! The chemicals used in this unit are contained within fully enclosed systems. No maintenance activities involving the refrigeration system are to be performed by the end-user.

Hot Surface! The compressor and associated tubing in the lower portion of the unit are likely to be hot and pose a potential burn hazard.

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Operator’s Manual: RS Series Chiller Chapter 6: Maintenance

Lockout/Tagout Procedure

To prevent accidental or unauthorized starting of this unit during maintenance, disconnect the power cord and install an appropriate lockout device on the end of the power cord. The necessary equipment should be available to allow the user to comply with OSHA 29 CFR 1910.147 (Control of Hazardous Energies, Lockout/Tagout) and 29 CFR 1910.331-335 (Electrical Safety - Related Work Practices) as related to lockout/tagout.

This unit is provided with a line cord with a standard NEMA 5-15P or 6-15P. Lockout of the equipment can be accomplished at the end of the equipment’s power cord.

Removal of Panel

•Ensure the line cord is unplugged and

tagged-out.

•Loosen and remove screws along edges

of the rear panel and grill.

•Remove reservoir lid

•Pull off panel back and up to remove.

•Place it out of the way.

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Operator’s Manual: RS Series Chiller Chapter 6: Maintenance

Fuse Replacement

Warning! Hazardous voltages. For continued protection against risk of

fire or shock, replace fuses only with those of same type and rating. Qualified service personnel must perform replacement.

Notice! Only qualified personnel should perform maintenance on the system.

NOTE: Replace Fuses with only the type and rating specified by the orange label.

Fuse

Location

Page 45

Operator’s Manual: RS Series Chiller Chapter 6: Maintenance

Cleaning

Warning! Hazardous voltages. Risk of electric shock. Disconnect all power

before servicing this unit. Refer servicing to qualified service personnel.

Notice! Only qualified personnel should perform maintenance on the system.

Caution! Proper safety equipment such as eye and face protection, gloves and dust mask should be used.

The following procedure should be followed on a routine basis, from weekly to monthly depending upon the operating environment.

•Disconnect electric utilities.

•Wipe down all exterior cabinet surfaces with a damp cleaning cloth.

•Check switch for proper operation.

•Vacuum dust from the refrigeration condenser as well as all screens and

openings.

•Remove cabinet panels.

•Blow compressed air systematically from the top to bottom. Let air settle for

several minutes and repeat.

•Check for areas that have frosted during operation and insulate as required.

•Replace cabinet panels.

•Connect electric utilities.

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Operator’s Manual: RS Series Chiller Chapter 6: Maintenance

Draining Fluid

Always use caution when handling fluids, filling or draining the system reservoir, or working in or around the chiller. Always wear protective eyewear when operating the chiller.

The user may need to drain the unit for any number of reasons: to replace the fluid, to change the type of fluid used, during maintenance, during repairs, etc. To drain the unit:

•Place a large low pan underneath the black

drain hose (the hose pulls out for easier access)

•With a screw driver loosen the clamp on the

end of the drain hose

•Remove the plug.

•

When the unit is completely drained:

•Replace the plug.

•Reposition and tighten the hose clamp.

Page 47

Chapter

Troubleshooting

NOTICE!

EPA certified technicians should evacuate or charge refrigerants.

PROBLEM POSSIBLE CAUSE SOLUTIONS

UNIT WILL NOT START

PUMP WILL NOT START

Only qualified personnel should perform maintenance on the refrigeration system, and only

Power is not connected properly Have electrician check power connections Breaker at the wall is in the "off" position Turn breaker "on". Fuse has blown Have qualified person check and replace fuse. Power is not connected properly. Have electrician check power connections. Breaker at the wall is in the "off" position Turn breaker "on". Pump is not primed Prime pump. Impeller jammed Verify that motor is getting voltage and that the voltage

is correct. If the fluid freezes it will jam the pump impeller

Pump motor has overheated The pump motor is provided with a thermal overload

protection. If it overheats, the pump will shut down; it will restart when the motor has cooled down. This is usually a result of the pump being overworked. Insure that the viscosity of the fluid being used remains <20 centistokes. Check solutions under "Fluid Flow is Inadequate".

Pump motor has burned out Very unlikely! If all reasons listed above are not the

cause and the pump has voltage to it, the pump motor is no good. Contact factory for a new motor.

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Operator’s Manual: RS Series Chiller Chapter 7: Troubleshooting

UNIT NOT COOLING PROPERLY

Temperature setting above fluid temperature Viscosity of fluid is too High for intended temperature range. Ambient temperature too high. To meet specifications the room air temperature must

Plumbing incorrectly connected to process.

Heat load is above unit’s rating Check so see that all lines have adequate insulation,

Adjust temperature setting to the proper setting

Change fluid.

be 72°F/22°C. The capacity of the cooling system and the maximum low temperature will degrade as the temperature increases Check that "LIQUID OUT" port of system is connected to inlet of system to be cooled, and that "LIQUID IN" is connected to outlet of system to be cooled

and that there are no local sources of heat that may be contributing to the load.

Refrigerant leak. Enlist a qualified, certified refrigeration technician to

connect gauges and check static charge. If this confirms a leak, have the system leak checked, repair leak, and recharge system to proper level.

Contact the FTS Service Dept. for assistance in leak checking and charging the system if needed.

EMPERATURE

ONTROLLER

WILL NOT

ONTROL

EMPERATURE

Controlling but not ve r y well? See controller instructions for PID tuning

FLUID FLOW IS INADEQUATE

Ball valve is closed Open ball valve Fluid flow is inadequate See "FLUID FLOW IS INADEQUATE Cooling valve is sticking Adjust temperature set point to cycle the cool indicator

on/off. This should result in a 'clicking' sound from inside the machine

Open Sensor. Measure resistance of sensor. It should be

approximately 100 ohms. If it is not, a new sensor is needed. Contact Service Dept. for new sensor

Connection on controller has come loose Check all connections on controller inside the unit. If

any are loose or disconnected, reconnect them

Low voltage to solenoid valves The controller is operating properly but because of

inadequate voltage to solenoid valve, the valves are not opening and closing as needed. Correct voltage supplied to the unit.

Defective solenoid valve The controller operating properly, but the solenoid

valve is not responding because of a defect. Replace coil. If problem still persists contact service

department Viscosity of fluid is too high for intended temperature range Pump screen blocked (if using a high pressure pump such as HPP2) Ball valve is closed Open ball valve Plumbing lines have become restricted or broken

Change fluid to a fluid with lower viscosity.

The inlet to the pump has a screen filter that is

accessed by removing the insulation from the pump

and removing the large nut on the pump housing.

Check plumbing lines and repair as necessary

Page 49

Operator’s Manual: RS Series Chiller Chapter 7: Troubleshooting

REFRIGERATION WILL NOT START

REFRIGERATION CUTTING OUT

PUMP IS MAKING LOUD NOISE

Restrictions in the system will not allow needed flow with supplied pump

Impeller of pump has been damaged Remove pump and check impeller, contact factory for

Pump motor has overheated The pump motor is provided with a thermal overload

Pump motor has burned out. Contact service department for new pump motor “0/1" switch was not pressed Press “0/1" button. Fluid pump starts first.

Voltage is inadequate. The compressor must have adequate voltage to start.

Ambient too warm The unit is designed for operation in an ambient

Fan not working Check the fan for rotation. If the fan is not rotating

Condenser blocked. The finned condenser requires adequate airflow to

Blocked filter screen (on high pressure pumps only)

Fluid freezing or icing Make sure that there is no ice in the fluid. Straight

Use larger line sizes. Replace pump with pump capable of supplying needed flow with the given plumbing restrictions. Check with factory for warranty implications

replacement pump or impeller. Determine cause of damage and correct cause to prevent future damage

protection. If it overheats, the pump will shut down; it will restart when the motor has cooled down. This is usually a result of the pump being overworked. Check the above items to see if they are causing the motor to overheat

Refrigeration starts several seconds later

Check voltage when power is applied to the system. If voltage is not within +/- 5% of the system rated voltage, contact the electrical department to have the voltage corrected

environment of 72°F/22°C. Temperatures over 80°F/27°C may cause the compressor to overheat.

check:

- AC supply to the fan.

- For blockage.

- Excessive dirt/dust.

provide cooling. Make sure that the finned surface is 6" away from the wall and not clogged with dust Enlist a qualified technician to remove filter screen by cutting back insulation and removing large nut on pump housing.

water should not be used below 5°C. For lower temperature operation mix with glycol.

NO HEATING

Standard

Fluid operating above overtemp set point.

models do not have heaters and rely on the

Overtemp sensor open or not making good contact.

load for the addition of heat.

Cooling valve sticking open Adjust the temperature set point to turn the cool

The overtemp is factory set for protection of the equipment. DO NOT READJUST WITHOUT FTS SERVICE AUTHORIZATION. Verify that the heater is NOT getting AC

indicator on/off. As the light

As the light alternates, the valve clicks open/close. This should regulate the temperature at setpoint. If not, the valve/coil must be replaced.

Page 50

Service

Maintenance and troubleshooting of your FTS equipment should be performed only by a trained, qualified technician.

If you require service on your unit please contact:

FTS Service Department 3538 Main Street, PO Box 158 Stone Ridge, N.Y. 12484

Telephone: 845-687-0063 or 877-548-4666 FAX: 845 687-0024 Email: [email protected]

FTS Warranties and Service Agreements

The FTS Service Division was founded in January of 1971. Our technicians are fully trained to service all electrical, refrigeration, liquid, vacuum, air, and vapor control systems manufactured and sold by FTS. We service all FTS products throughout the world from our home office located at the FTS manufacturing facility in Stone Ridge, New York.

In addition to factory support personnel, we have a worldwide network of qualified service organizations ready to accommodate you and your service needs.

Customer satisfaction is our number one priority. Our goal is to provide the finest quality service promptly at the best price possible. We recognize that a satisfied customer is our most valuable asset!

A timely solution to a service problem is best achieved by establishing good communication with the FTS Service Division. We will furnish the appropriate qualified service support group for your area. Should you require repair services or parts for your FTS equipment please contact us at your convenience. We will discuss your requirements and suggest the best means to get you back on line as fast as possible.

Chapter

Page 51

Operator’s Manual: RS Series Chiller Chapter 8: Service & Warranties

Standard Warranty

The FTS standard domestic warranty follows. This warranty covers parts and labor for a period of one year, commencing the date of invoice, for any repairs deemed resultant of a defect in materials and/or workmanship by FTS, F.O.B. Stone Ridge.

Any factory approved changes or extensions to this warranty should be received in writing from FTS and filed with this warranty. If your system is eligible for coverage, please review this warranty thoroughly and contact the FTS Service Division with any questions you may have. If your system is not covered by our standard warranty, or you are seeking optional or additional coverage, see sections below for service plans offered.

Covered:

• Parts and labor for a period of one (1) year from date of delivery. Any part found defective will be either repaired or replaced at FTS discretion, free of charges by FTS, at Stone Ridge, N.Y.

• On site labor if repairs require that FTS personnel travel to the equipment.

• Necessary parts and reasonable labor charges, if FTS agrees that local service is

preferable. These parts and labor charges are subject to written approval prior to initiating the repair.

• Travel time, mileage, travel and transportation expenses expended by FTS personnel if repairs require on-site labor.

• Transportation of the equipment for repair.

Not Covered:

• FTS is not responsible for incidental or consequential damages, or damage resulting from negligence.

This writing is a final and complete integration of the agreement between the customer and FTS. FTS makes no other warranties express or implied, of merchantability, fitness or otherwise, with respect to the goods sold under this agreement, which extend beyond the description of this limited warranty.

FTS will have the right to inspect the equipment and determine the repairs or replacements necessary. The customer will be notified within a reasonable time of any damages incurred that are not covered by this warranty prior to initiation of any such repairs.

Any customer modification of this equipment, or any repairs undertaken without the prior written consent of FTS will render this limited warranty void.

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Operator’s Manual: RS Series Chiller Chapter 8: Service & Warranties

Service Options

Extended Warranty:

This plan is an extension to the original new purchase warranty. You may extend the original warranty for one or two years total coverage. This plan does not provide Preventative Maintenance, nor does it cover travel or any freight expenses incurred.

Preventative Maintenance:

This plan provides our customers with one or two onsite visits per year. We would perform a thorough preventative maintenance on your FTS equipment. You will be provided with a PM checklist and a certificate of calibration, which is traceable to N.I.S.T. The purchase of this plan also provides discounted parts and labor rate for additional service if deemed necessary at the time of the PM.

Service Contract:

Service contracts (SC) are available post-expiration of any warrant period (standard or extended). SCs provide companies a plan which includes travel, labor, and priority response time. Any necessary parts are provided at a discounted rate. Two levels (silver and gold) are available for varying customer needs.

Contact FTS Service at (845) 687-0063 or (877) 548-4666 for details.

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Operator’s Manual: RS Series Chiller Chapter 8: Service & Warranties

Return of FTS Equipment

If it is necessary to return the equipment to our factory, please contact the FTS Service Division at (800) 722-7721 for a Return Authorization (RA) number, and instructions on returning the unit. Please provide the model number, serial number, and order number. After receiving an RA number, return the unit, freight prepaid, to the following address:

FTS, Inc. 3538 Main Street PO Box 158 Stone Ridge, N.Y. 12484 U.S.A. Attn: Service Division RA# _________

Make sure the RA number and the declared value of the unit is plainly marked on your shipping label.

FTS will refuse any equipment returned without a RA number, without freight prepaid, or with an expired RA number. This number is valid for 30 days; if your RA number expires you must request a new number.

Before working on systems that are not under warranty, the Service Division will provide you with an estimate of the time and cost for the repair of your unit. No work will be started until FTS receives a hardcopy of your purchase order for the repair work. This also applies to warranty work when the customer is responsible for the shipping costs.

If your repair is urgent, you may authorize an emergency repair fee, which guarantees priority service.

Unless you specify otherwise, we will return the repaired unit F.O.B. from our Stone Ridge, New York factory, via ground transportation.