Hypertherm DuraChill 5 HP User Manual

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Operators Manual

DuraChill™ 5 HP Air-Cooled Chiller

®

For Hypertherm

110-482

05-21-10

806600r0

Table of Contents

Section 1 – Safety and Warranty Information

1.1 Safety

1.2 Warranty

1.3 Unpacking

Section 2 – Introduction

Section 3 – Specifications

Section 4 – Installation and Startup

Section 5 – Normal Operation

2.1 General Description

2.2 Component Identification

2.2.1 Control System

2.2.2 Fluid Circulation System

2.2.3 Cooling System

3.1 Air-Cooled Chillers — DA 500

4.1 Site Requirements

4.1.1 Ambient Temperature and Relative Humidity

4.1.2 Location

4.1.3 Clearance

4.2 Plumbing

4.2.1 Process Piping

4.2.2 Reservoir Vent

4.2.3 Reservoir Drain

4.3 Reservoir Low Level Float Switch Alarm

4.4 Fan

4.5 Electrical Power

4.5.1 Power Phase Requirements

4.5.2 Remote On / Off

4.6 Startup

4.6.1 Process Coolant

4.6.2 Starting Process Fluid Flow

4.6.3 Adjusting the Set Point

4.6.4 Selecting Celsius or Fahrenheit

5.1 Power On

5.2 Controller Display / Menu Structure

5.3 Controller Display / Menu Navigation

5.4 Checking / Adjusting Set Point

5.5 Selecting Celsius or Fahrenheit (ºC or ºF)

5.6 Pressure Display – 0 to 247 psi; 0 to 1700 kPa

5.7 High Temperature Limit (HL)

5.8 Low Temperature Limit Value (LL)

5.9 High Ambient Temperature Limit (HA)

5.10 Low Temperature Band (Compressor Turn Off)

5.11 Upper Temperature Band (Compressor Turn On)

5.12 Temperature Calibration Offset (c1)

5.13 Low Ambient Temperature Alarm Setting (LA)

5.14 Controller Operating, Alarm, and Error Messages

5.15 Dual Float Switch

5.16 Loss of Power

5.17 High Pressure Bypass Setting

5.18 Enabling/Disabling the Local Lockout

5.19 Automatic Restart from Alarm Mode

5.20 Fuse Bits

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Section 6 – Routine Maintenance

6.1 Recommended Routine Maintenance Schedule

6.2 Routine Maintenance Procedures

6.2.1 Inline Strainers

6.2.2 Reservoir Coolant Level

6.2.3 Coolant Freeze Protection

6.2.4 Air Filters

Section 7 – Troubleshooting

7.1 Unit will not operate (no cooling or pumping)

7.2 No Pumping

7.3 Insufficient Pumping

7.4 No Cooling or Insufficient Cooling

7.5 Triac Failure

7.6 Internal Probe Failure

7.7 Pump Overload Fault “Ft 19”

7.8 Fan Overload Fault “Ft 21”

7.9 Compressor Overload “Ft 20””

Section 8 - Service and Technical Support
Appendix

A.1 Flow Diagram
A.2 Wiring Diagram
A.3 Parts Replacement

This symbol marks chapters and sections of this instruction manual which are particularly relevant to safety. When
attached to the unit, this symbol draws attention to the relevant section of the instruction manual.

This symbol indicates that hazardous voltages may be present.

Read all instructions pertaining to safety, set-up, and operation.

Proper operation is the users’ responsibility.

Section 1 – Safety and Warranty Information

1.1 Safety

It is the user’s responsibility to read and understand all instructions and safet y precautions included in this manual
prior to installing or operating this equipment. Contact our Customer Service Department with any questions
regarding the operation of this chiller or the information contained in this manual.

Installation, operation, or maintenance of this equipment should be performed in strict
accordance with the instructions outlined in this manual. Failure to follow those instructions may
increase the risk of personal injury, damage the equipment, and/or void the warranty.

Exercise care when unloading, loading, rigging, or moving this equipment.

All warning labels should be carefully observed. Never remove or obstruct a warning labe l.

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Make sure that ventilation is adequate when welding or brazing around this equipment. Protect
adjacent materials from flames or sparks. Keep an approved fire extinguisher close at hand.

Always operate this equipment within the stated design specifications.

Be sure to remove power from the equipment, reclaim the refrigeration charge, and relieve any
residual pressure before cutting into the refrigeration system.

Do not attempt to operate leaking or damaged equipment.

Service should only be performed by fully qualified personnel.

Follow all applicable electrical and safety codes when connecting power to this equipment.

Do not attempt to override the power interlock switch or any other safety features on this
equipment.

Always remove power from the equipment prior to performing any service or maintenance.

Do not move the equipment without first disconnecting power.

Make sure the equipment’s main power switch is in the OFF position before connecting or
disconnecting power.

Additional Precautions

Do not attempt to operate this equipment without an appropriate cooling fluid in the reservoir.
Always empty the fluid reservoir before moving the unit.

1.2 Warranty

Thank you for purchasing this chiller. We are confident it will serve you for a long time. Our warranty to you is as
follows:

The manufacturer agrees to correct for the original user of this product, either by repair, or at the manufacturer's
election, by replacement, any defect that develops after delivery of this product within the period as stated on the
warranty card. In the event of replacement, the replacement unit will be warranted for 90 days or warranted for the
remainder of the original unit’s parts or labor warranty period, whichever is longer.

If this product requires service, contact the manufacturer/supplier's office for instructions. When return of the product
is necessary, a return authorization number will be assigned and the product should be shipped, (transportation

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charges pre-paid), to the indicated service center. To insure prompt handling, the return authorization number should
be placed on the outside of the package and a detailed explanation of the defect enclosed with the item.

This warranty shall not apply if the defect or malfunction was caused by accident, negl ect, unreasonable use,
improper service, or other causes not arising out of defects in material or workmanship. There are no warranties,
expressed or implied, including, but not limited to, those of merchantability or fitness for a particular purpose which
extends beyond the description and period set forth herein.

The manufacturer's sole obligation under this warranty is limited to the repair or replacement of a defe c tive product
and shall not, in any event, be liable for any incidental or consequential damages of any kind resulting from use or
possession of this product. Some states do not allow: (A) limitations on how long an implied warranty lasts; or (B) the
exclusion or limitation of incidental or consequential damages, so the above limitations or exclusions may not apply to
you. This warranty gives you specific legal rights. You may have other rights that vary from state to state.

1.3 Unpacking

Your chiller is shipped in a special container. Retain the container and all packing materials until the unit i s
completely assembled and working properly. Set up and run the unit imm ediately to confirm proper operation.
Beyond one week, your unit may be warranty repaired, but not replaced. If the unit is damaged or does not operate
properly, contact the transportation company, file a damage claim and contact the company where your unit was
purchased immediately.

Section 2 – Introduction

2.1 General Description

®

The PolyScience
self-contained chiller is engineered to provide accurate temperature control.

Standard Features

• Process temperatures from 32° to 86°F (0° to 30°C)

• Ambient temperatures from 14° to 104°F (-10° to 40°C)

• ±2°F (±1.11°C) temperature stability

• High efficiency vertical air exhaust

• Accurate microprocessor control with LED temperature readout

• Over/under temperature process fluid alarms

• Copeland Scroll

• Stainless steel centrifugal pump

• Integral pump and compressor protection

• Locking casters

• NEMA 12 style electrical enclosure with door-mounted power disconnect

• Power phase monitor

• Full Flow Bypass Valve

• Low tank level indicator/alarm – Dual Float Switch

DuraChill™ chiller offers exceptional performance, reliability, and operational simp licity. This robust

®

compressor

2.2 Component Identification

Your Chiller consists of three basic sub-systems:

• Control system

• Fluid circulation system

• Cooling system

This section describes these sub-systems in detail and includes information on the av ailable options.
See Sections A.1 and A.2.

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2.2.1 Control System

This system controls and monitors Chiller operation. It consists of a microprocessor-based controller linked to the
various sensors, gauges, valves, switches, and signal input/output connections on the unit.

Control Panel

— Temperature set point, temperature units, and other operating parameters are set via the Control

Panel. Operating information is displayed on a local LED readout.
TEMPERATURE CONTROLLER PCB = Part No.: 500-367
POWER SUPPLY PCB

= Part No.: 215-513

Pressure/Flow Display

Power Switch / Disconnect
functions as a power disconnect when access to the unit’s electrical components and terminal blocks is required; the
access door cannot be opened until the Power Switch / Disconnect is placed in the Off position.

DISCONNECT SWITCH
Temperature Probe — An internal RTD is used to measure fluid temperature downstream of the pump. Its reading is

displayed on the Control Panel LED.
PLATINUM TEMPERATURE PROBE = Part No.: 200-450
Pressure Sensor

— Measures fluid pressure at the outlet of the Chiller.

PRESSURE TRANSDUCER

2.2.2 Fluid Circulation System

This system governs the circulation of fluid through the unit.
Reservoir Tank — This polyethylene tank is used to maintain stable temperature control and an adequate reserve of

fluid for the system. It is equipped with a float switch that monitors fluid level and activates an alarm if the level drops
too low.

Tank Sight Glass or Level Indicator
the Reservoir Tank.

Process Pump

— The high pressure turbine pump is used to pump fluid from the Reservoir Tank to the process.
1HP TURBINE PUMP
200-240/380-460V 50/60Hz = Part No.: 505-174
575-600V 60Hz = Part No.: 505-178
Recirculation Pump — The stainless steel centrifugal pump assures adequate flow through the evaporator to optimize

heat transfer.
½ HP CENTRIFUGAL PUMP
200-240/380-460V 50/60HZ = Part No.: 505-175
575-600V 60HZ = Part No.: 505-177

Units/Menu

Select Button

Temperature Display

Select/Set Knob

Power Button

— The main power switch is located on the front door of the unit. This switch also

= Part No.: 215-629

= Part No.: 750-757

— This indicator serves as a convenient means of checking the liquid level within

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Dual Float Switch — If fluid level should fall below the upper float switch (7 gallons low) the right hand display will
alternately show “EFL” and fluid temperature, Audible alarm will intermittently sound. This will continue indefinitely
until attended to.

If fluid level should fall below the lower float switch (9 gallons low) the right hand display will alternately show “EF2”
and fluid temperature, Audible alarm will intermittently sound and after a delay the unit will turn off.

DUAL FLOAT S WITCH
Flow Switch

— Monitors internal recirculation flow. If flow rate is less than 4 gpm or fluid level in reservoir is below

= Part No.: 235-064

lower float switch an alarm message - “EF2” is displayed and chiller turns off.
FLOW SWITCH

= Part No.: 235-052
Strainer — Traps debris which could potentially clog the Evaporator.
RECIRCULATION PUMP ‘Y’ FILTER (3/4”)
PROCESS OUTLET ‘Y’ FILTER (1/2”)
Bypass Valve

— Used to prevent overloading of pump in the event that the process piping becomes restricted or

clogged. Diverts flow from process line back to Reservoir Tank.
200 PSI PRESSURE RELIEF VALVE

2.2.3 Cooling System

The condenser on your Chiller is air-cooled. The following components are common to all systems.

Common Cooling System Components

Evaporator

— Serves as the heat exchanger between the refrigeration and fluid flow system. Cools fluid before it

returns to process.
BRAZED PLATE HEAT EXCHANGER = Part No.: 750-214
Compressor

— The unit incorporates a 5-HP Copeland Scroll® compressor. The Compressor is protected from

overloads through high and low refrigerant pressure cutouts.
5HP COMPRESSOR
200-230V 50/60Hz = Part No.: 750-833
380-460V 50/60HZ = Part No.: 750-813
575-600V 60HZ = Part No.: 750-832
Filter Dryer

— Removes residual particulate and moisture from the refrigeration system. Must be replaced whenever

the sealed refrigeration lines are opened for service.

FILTER DRYER = Part No.: 750-229

Sight Glass
SIGHT GLASS
Expansion Valve

— Used to observe refrigerant liquid flow to Evaporator.

= Part No.: 750-230

— Controls refrigerant superheat at the outlet of the Evaporator to prevent liquid from returning to

the compressor.
TXV (Thermostatic Expansion Valve) = Part No.: 750-814
Hot Gas Bypass Solenoid Valve

— Injects refrigerant vapor into the Evaporator to stabilize temperature control when

operating at less than a full heat load.
SOLENOID VALVE = Part No.: 750-222
COIL = Part No.: 750-216
Refrigerant Relief Valve

— Automatic safety used to vent refrigeration gas in the event that pressure exceeds a

factory set value. This valve is set to open at 650 PSI.
SAFETY RELIEF VALVE ¾ MPT (650PSI) = Part No.: 750-815

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= Part No.: 400-710

Part No.: 775-174

= Part No.: 776-090

Condensing Fan — A 1 HP fan that draws air over the condenser coils to cool refrigerant gas. The standard fan is
fixed speed and cycles on/off based on refrigerant pressure. It turns on when refrigerant pressure is 400 PSI or
greater, turns off when refrigerant pressure falls below 300 PSI.

1HP FAN MOTOR

200-240/380-460V 50/60 Hz =
575-600V 60 Hz = Part No.: 215-603

Refrigerant Pressure Switches — These switches automatically disconnect power from the condenser system in the
event that refrigerant pressure is outside factory set high/low values. The Low Pressure Switch is set to open at 10
PSI and close at 30 PSI. The High Pressure Switch is set to cutout at 630 PSI.

HIGH PRESSURE CUTOUT SWITCH
LOW PRESSURE CUTOUT SWITCH
Fan Cycling Switch

pressure reaches 400 PSI; it is turned Off when the discharge pressure drops below 300 PSI.
FAN CYCLING SWITCH = Part No.: 215-726

— This switch controls fan operation. The fan is turned On when the compressor discharge

Section 3 – Specifications

3.1

Part No.: 215-435

= Part No.: 235-071

= Part No.: 215-436

Model DA500

Process Temperature 32° to 86°F (0° to 30°C)

Temperature Stability ±2.0°F (±1.11°C)

Ambient Operating Temperature 14° to 104°F (-10° to 40°C)

Compressor (nominal HP) 5 HP Copeland Scroll®

1, Capacity based on 95°F (35°C) entering air and 120°F (49°C) condensing temperature.
Leaving water 50°F (10°C). Allowance made for heat gain from pump.

2. Flow rate based on 2.4 GPM (US) per ton (0.54m

Refrigerant Charge (R-410A) 10 lbs.

Cooling Capacity1

Nominal Evaporator Flow2

GPM (US)

Fan 1 HP

Condenser Discharge Air Flow 3,500 CFM

Reservoir Tank Capacity 16 gallons

Dimensions (D x W x H) 54 x 34.5 x 67 inches

Shipping Weight 990 Lb. (449 Kg)

Voltage ±10%

200-240V, 3 phase,50/60Hz

380-440V, 3 phase, 50Hz

460-480V, 3 phase, 60Hz

575-600V, 3 phase, 60Hz

55,920 BTU/hr

Nominal Rated Amps

3

/hr/ton)

4.66 tons

16,384 watts

11.7

30 A
20 A
15 A
12 A

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Section 4 – Installation and Startup

4.1 Site Requirements

4.1.1 Ambient Temperature and Relative Humidity

The Chiller is designed for indoor installation in ambient temperatures between 14° and 104°F (-10° to 40°C); relative
humidity should be between 20% and 80% (non-condensing).

4.1.2 Location

The Chiller should be installed on a level surface capable of supporting 990 pounds (449 kg) or more and should be
located as close to possible to the process requiring cooling. It should not be installed closer than 4 feet (1.4 meters)
to a heat generating source, such as heating pipes, boilers, etc.). If possible, it should be located near a suitable drain
to prevent flooding in the event of leaks.

For ease of final positioning and maneuverability, the Chiller is supplied with four heavy-duty locking casters. Use
fork lift if moving more than 20 feet.

4.1.3 Clearance

At least 18 to 24 inches (45.7 to 61 cm) of clearance should be allowed on the front, sides, and rear of the Chiller for
access to connections and components. Chillers require at least 4 feet (1.4 meters) of overhead clearance to
dissipate the exhaust from the Chiller’s top-mounted fan.

4.2 Plumbing

See Figure 4-1

4.2.1 Process Piping

The Chiller incorporates two 1/2” MPT x ¾”- 16 male 37
process inlet and outlet connections.

To maintain a safe workplace and to avoid leaks, special care should be taken when choosing hoses and
connections for the Chiller.

• Pressure Ratings — Hoses should be able to withstand a minimum of 250 PSI.

• Flexible Tubing — Avoid tubing that will expand and take up fluid volume when operating at the desired

pressure.

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° flare, #8 JIC fittings on the rear of the enclosure for the