PolyScience Refrigerated Recirculating Chillers, 6206, 6306, 6506, 6706 Operator's Manual

Operators Manual

Refrigerated Recirculating Chillers

110-240 Rev. H

06/06

EC Declaration of Conformity

The Products herewith complies with the requirements, as stated below, in accordance to the EC Low Voltage
Directive 73/23/EEC and EC Electromagnetic Compatibility Directive 89/336/EEC, and carries the marking

accordingly.

We herewith declare:

That the following equipment complies with the essential requirements in respect to safety and health, in
accordance to the EC Directives based on its design and type, as brought into circulation by us. In case of
alteration of the equipment, not agreed upon by us, this will lose its validity.

Product Description: Refrigerated Chillers

Testing Bodies:

PolyScience
Division of Preston Industries, Inc.
6600 West Touhy Avenue
P.O. Box 48312
Niles, Illinois 60714, USA

6206, 6306, 6506, 6706, 6106, 5206, 5306, 5706, 5106; 1171, 1173, 1175,
1177, 1179, 512CR, 517CR

Low Voltage Directive 73/23/EEC & Electromagnetic Compatibility
89/336/EEC and relevant transpositions into national law of the
member states, including, but not limited to the following
Harmonized Standards:
EN/IEC 61010-1: 2001
EN/IEC 61010-2
EN 61326: 1997 +A1: 1998 + A2:2001
CISPR 11/EN 55011 Class A, Group I

CSA International (Certification & Testing Division)
D.L.S. Electronic Systems Inc. ( EMC approval)

Signature on Behalf of
Manufacturer or Authorized

Representative:
Date of Validity:
Title of Signatory:

110-266 Rev. D 10/05

Brian Klotz
October 18, 2005
Engineering Manager

2

WEEE Directive

A label with a crossed-out wheeled bin symbol and a rectangular bar indicates that the product
is covered by the Waste Electrical and Electronic Equipment (WEEE) Directive and is not to
be disposed of as unsorted municipal waste.

Any products marked with this symbol must be collected separately, according to the
regulatory guidelines in your area.

The objectives of this program are to preserve, protect and improve the quality of the
environment, protect human health, and utilize natural resources prudently and rationally.
Specific treatment of WEEE is indispensable in order to avoid the dispersion of pollutants into
the recycled material or waste stream. Such treatment is the most effective means of protecting
the customer’s environment.

Requirements for waste collection, reuse, recycling, and recovery programs vary by regulatory
authority at your location.

Contact your local responsible body (e.g., your laboratory manager) or authorized
representative for information regarding applicable disposal regulations.

Contact PolyScience at the web site listed below for information.

Web address: www.polyscience.com

Customer Care: 1-800-229-7569 (inside the USA)
([phone] (outside the USA)
Fax [phone]

or

3

Table of Contents

Section 1 - General Information

1.1 Warranty

1.2 Unpacking

Section 2 – Overview

2.1 Contents

2.2 Description

2.3 Chiller Specifications and Pump Performance

Section 3 – Installation and Startup

3.1 Site Requirements

3.2 Electrical Power

3.3 Optional Signal Inputs/Outputs

3.4 Plumbing

3.5 Closed System or Cooling Coil Setup

3.6 Open Bath System Setup

3.7 Startup

Section 4 – Operation

4.1 Selecting the Temperature Unit (°C or °F)

4.2 Displaying and Adjusting the Set Point

4.3 Displaying and Adjusting the Ambient Tracking Offset

4.4 Displaying and Adjusting Remote Control Temperature

4.5 Selecting the Pressure / Flow Rate Display and Units

4.6 Selecting Internal/External Temperature Display

4.7 Setting Operational Parameters

4.8 Display, Alarm, and Error Messages

4.9 Adjusting the High Pressure Bypass Setting

4.10 Enabling/Disabling the Local Lockout

Section 5 – Maintenance and Calibration

5.1 Standard Magnetic Drive Centrifugal Pump

5.2 Condenser, Air Vents, and Reusable Filter

5.3 Fluid Filter

5.4 Fluid Level

5.5 Temperature Calibration

5.6 Flow Rate Calibration

Section 6 - Troubleshooting

6.1 Unit Will Not Operate (No Cooling or Pumping)

6.2 No Pumping

6.3 Insufficient Pumping

6.4 No Cooling or Insufficient Cooling

6.5 Triac Failure

6.6 Internal Probe Failure

6.7 External Temperature Probe Failure

6.8 Diagnostic Mode

Section 7 - Service and Technical Support

7.1 Electrical Wiring Diagram

7.2 Process Flow Diagram

Section 8 - Replacement Parts

Section 9 – RS232

4

Section 1 - General Information

1.1 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 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, neglect,
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
defective 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.

1.2 Unpacking

Your Chiller is shipped in a special carton. Retain the carton and all packing materials until the unit is
completely assembled and working properly. Set up and run the unit immediately 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.

This symbol marks chapters and sections of this instruction manual that 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.

5

Section 2 -- Overview

2.1 Contents

— Recirculating Chiller
— Operators Manual
— Warranty Card

— IEC Power Cord
— Two sets of Inlet/Outlet Adapters: ½ inch male NPT, 5/8 inch male NPT

2.2 Description

These Refrigerated Recirculating Chillers provide cooling power for demanding applications and
serve as an economical alternative to tap water cooling systems. All models feature a
microprocessor-based controller, digital temperature display (°C or °F), one-touch set point display,
and digital pressure/flow rate display (PSI, kPa, GPM, LPM) with push-button selection.

To optimize cooling efficiency and performance, these sophisticated Chillers also feature a
modulated refrigeration system. As a result, temperature stability is greatly enhanced and
compressor life extended.

Refrigerated Recirculating Chillers are equipped with either a centrifugal, positive displacement, or
regenerative turbine pump. Wetted parts within the recirculation system are brass, stainless steel,
polyethylene, EPDM rubber, and nylon.

4

6

7

12

1

2

15

3

9

10

13

8

Front/Top Rear

1. Temperature Display 9. Fluid Outlet

2. Select/Set Knob 10. Fluid Inlet

3. Power Button 11. Drain

4. Reservoir Cap and Internal Fluid Filter (top) 12. Reservoir Fluid Level Gauge

5. Air Filter 13. Circuit Breaker / Power Switch

6. Pressure / Flow Rate Display 14. IEC Power Connection

7. Units / Menu Select Button 15. Remote I/O Connection (optional)

8. Ambient Tracking Probe Connection (optional) 16. RS232 / RS 485 Connection (optional)

5

14

16

11

6

2.3 Chiller Specifications and Pump Performance

General Specifications (all Chillers)

Temperature Set Point Resolution ±0.1°C

Temperature Stability ±0.1°C

Temperature Units °C or °F

Pressure Units PSI or kPa

Pressure Display Resolution
Pressure Display Accuracy

1 PSI / 6.9 kPa
±3.5% of full scale (100PSI)

Flow Rate Units GPM or LPM

Flow Rate Display Resolution

Flow Rate Display Accuracy

0.1 GPM / 1 LPM

+/- 0.4 GPM / 1.5 LPM

Pump Inlet and Outlet ½ inch NPT

Pump Performance

¼ HP

1

/3 HP

½ HP

All Models

¾ HP

1 HP

Magnetic Drive Centrifugal Pump Positive Displacement Pump

¼ HP

1

/3 HP
½ HP
¾ HP

1 HP

Turbine Pump

7

Specifications — 1/4-HP, 1/3-HP, and 1/2-HP Chillers

Model: Rfg = Refrigerating Only
Rfg / Htg = Refrigerating & Heating

Magnetic Drive Centrifugal Pump

Model Rfg Rfg / Htg Rfg Rfg / Htg Rfg

Operating Temperature

Compressor 1/4 HP 1/3 HP 1/2 HP

Cooling Capacity @ 20°C
10°C
0°C

Pressure at 0 Flow Rate 10 psi / 69 kPa 10 psi / 69 kPa 10 psi / 69 kPa

Flow Rate at 0 psi 4.1 gpm / 15.5 lpm 4.1 gpm / 15.5 lpm 4.1 gpm / 15.5 lpm

Reservoir Capacity 1.1 gal / 4.2 liters 1.1 gal / 4.2 liters 1.1 gal / 4.2 liters

Dimensions (h x w x d)

Shipping Weight

120 V, 60 Hz Chillers

Volts Range

Amps 9.5A 10.0A 10.4A 10.7A 13.5A

240 V, 50 Hz Chillers

Volts Range
Over Voltage

Amps 5.6A 5.9A 5.9A 6.2A 7.2A

Positive Displacement Pump (“P” Series Chillers)

-10° to
40°C

800 watts 2728 BTU/hr
500 watts 1705 BTU/hr
200 watts 682 BTU/hr

131 pounds

59.4 kg

-10° to
70°C

-10° to
40°C

1200 watts 4092 BTU/hr
900 watts 3069 BTU/hr
500 watts 1705 BTU/hr

22-5/8 x 14-1/2 x 27-5/8 in.

57.5 x 36.8 x 70.2 cm

143 pounds

108 to 132V

198 to 264V

Category II

-10° to
70°C

64.8 kg

-10° to 40°C

1700 watts 5797 BTU/hr
1100 watts 3751 BTU/hr
750 watts 2557 BTU/hr

168 pounds

76.2 kg

Model P Series Chillers Rfg Rfg / Htg Rfg P Rfg / Htg Rfg

Operating Temperature

Compressor 1/4 HP 1/3 HP 1/2 HP

Cooling Capacity @ 20°C
10°C
0°C

Flow Rate @ 0 psi 1 gpm / 3.75 lpm 1 gpm / 3.75 lpm 1 gpm / 3.75 lpm

Pump Pressure (adjustable)

Reservoir Capacity 1.1 gal / 4.2 liters 1.1 gal / 4.2 liters 1.1 gal / 4.2 liters

Shipping Weight

120 V, 60 Hz Chillers

Volts Range

Amps 12.2A 12.5A 13.1A 13.5A 16.0A

240 V, 50 Hz Chillers

Volts Range
Over Voltage

Amps 6.8A 7.1A 7.3A 7.6A 8.9A

-10° to
40°C

800 watts 2728 BTU/hr
500 watts 1705 BTU/hr
200 watts 682 BTU/hr

20 to 100 psi

138 to 689 kPa

141 pounds

64 kg

-10°C to
70°C

-10° to
40°C

1200 watts 4092 BTU/hr
900 watts 3069 BTU/hr
500 watts 1705 BTU/hr

20 to 100 psi

138 to 689 kPa

153 pounds

108 to 132V

198 to 264V

-10°C to
70°C

69 kg

Category II

-10° to 40°C

1700 watts 5797 BTU/hr
1100 watts 3751 BTU/hr
750 watts 2557 BTU/hr

20 to 100 psi

138 to 689 kPa

178 pounds

81 kg

8

Model: Rfg = Refrigerating Only
Rfg / Htg = Refrigerating & Heating

Turbine Pump (“T” Series Chillers)

Model T Series Chillers Rfg Rfg / Htg Rfg Rfg / Htg Rfg

Operating Temperature

Compressor 1/4 HP 1/3 HP 1/2 HP

Cooling Capacity @ 20°C
10°C
0°C

Flow Rate @ 0 psi 3.5 gpm / 13.2 lpm 3.5 gpm / 13.2 lpm 3.5 gpm / 13.2 lpm

Pump Pressure (adjustable)

Reservoir Capacity 1.1 gal / 4.2 liters 1.1 gal / 4.2 liters 1.1 gal / 4.2 liters

Shipping Weight

120 V, 60 Hz Chillers

Volts Range

Amps 12.2A 12.5A 13.1A 13.5A 16.0A

240 V, 50 Hz Chillers

Volts Range
Over Voltage

Amps 6.8A 7.1A 7.3A 7.6A 8.9A

Specifications subject to change without notice.

-10° to
40°C

800 watts 2728 BTU/hr
500 watts 1705 BTU/hr
200 watts 682 BTU/hr

20 to 90 psi

138 to 621 kPa

143 pounds

65 kg

-10°C to
70°C

-10° to
40°C

1200 watts 4092 BTU/hr
900 watts 3069 BTU/hr
500 watts 1705 BTU/hr

20 to 90 psi

138 to 621 kPa

156 pounds

108 to 132V

198 to 264V

-10°C to
70°C

71 kg

Category II

-10° to 40°C

1700 watts 5797 BTU/hr
1100 watts 3751 BTU/hr
750 watts 2557 BTU/hr

20 to 90 psi

138 to 621 kPa

181 pounds

82 kg

9

Specifications — 3/4-HP and 1-HP Chillers

Model: Rfg = Refrigerating Only
Rfg / Htg = Refrigerating & Heating

Magnetic Drive Centrifugal Pump

Model Rfg Rfg / Htg Rfg Rfg / Htg

Operating Temperature -10° to 40°C -10° to 70°C -10° to 40°C -10 to 70°C

Compressor 3/4 HP 1 HP

Cooling Capacity @ 20°C
10°C
0°C

Pressure at 0 Flow Rate 10 psi / 69 kPa 10 psi / 69 kPa

Flow Rate at 0 psi 4.1 gpm / 15.5 lpm 4.1 gpm / 15.5 lpm

Reservoir Capacity 1.1 gal / 4.2 liters 1.1 gal / 4.2 liters

Dimensions (h x w x d)

Shipping Weight

208-230 V, 60 Hz

Volts Range

Amps 9.2A 9.5A 9.5A 9.8A

240 V, 50 Hz

Volts Range
Over Voltage

Amps 9.2A 9.5A 9.5A 9.8A

2500 watts 8525 BTU/hr
1700 watts 5797 BTU/hr
760 watts 2591 BTU/hr

22-5/8 x 14-1/2 x 27-5/8 in.

57.6 x 36.8 x 70.2 cm

187 pounds

84.8 kg

187 to 253V

198 to 264V

Category II

2900 watts 9889 BTU/hr
1950 watts 6649 BTU/hr
1000 watts 3410 BTU/hr

189 pounds

85.7 kg

Positive Displacement Pump (“P” Series Chillers)

Model P Series Chillers Rfg Rfg / Htg Rfg Rfg / Htg

Operating Temperature -10° to 40°C -10° to 70°C -10° to 40°C -10° to 70°C

Compressor 3/4 HP 1 HP

Cooling Capacity @ 20°C
10°C
0°C

Flow Rate @ 0 psi 3.5 gpm / 13.2 lpm 3.5 gpm / 13.2 lpm

Pump Pressure (adjustable)

Reservoir Capacity 1.1 gal / 4.2 liters 1.1 gal / 4.2 liters

Shipping Weight

208-230 V, 60 Hz

Volts Range

Amps 11.9A 12.2A 12.2A 12.5A

240 V, 50 Hz

Volts Range
Over Voltage

Amps 11.9A 12.2A 12.2A 12.5A

2500 watts 8525 BTU/hr
1700 watts 5797 BTU/hr
760 watts 2591 BTU/hr

20 to 100 psi

138 to 689 kPa

197 pounds

89 kg

187 to 253V

198 to 264V

Category II

2900 watts 9889 BTU/hr
1950 watts 6649 BTU/hr
1000 watts 3410 BTU/hr

20 to 100 psi

138 to 689 kPa

199 pounds

90 kg

10