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6860T56A270D
User manual
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PolyScience 6960P46A270D, 6860P46A270D, 6860T56A270D, 6850P46A270E, 6850T56A270E User manual

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DuraChill Air- and Water-Cooled 1.5 HP Chillers
07 February 2020
www.GlobalTestSupply.com
110-392
Table of Contents
Introduction ...............................................................................................................................................................3
General Safety Information .....................................................................................................................................3
Safety Recommendations .......................................................................................................................................3
Regulatory and Compliance Testing ...................................................................................................................5
Contents ..................................................................................................................................................................5
Controls and Components ......................................................................................................................................6
Control Panel .......................................................................................................................................................6
Front ....................................................................................................................................................................6
Rear -- 230V, 240V, and 208-230V Units ...........................................................................................................7
Rear -- 380V and 460V Units ..............................................................................................................................7
Quick Start .................................................................................................................................................................8
Installation and Startup ............................................................................................................................................9
Site Requirements ...................................................................................................................................................9
Ambient Temperature and Relative Humidity .....................................................................................................9
Location ...............................................................................................................................................................9
Clearance ............................................................................................................................................................9
External Piping ..................................................................................................................................................... 10
General Considerations .................................................................................................................................... 10
Process Fluid Connections ............................................................................................................................... 11
Facility Water Connections ............................................................................................................................... 11
Reservoir Drain................................................................................................................................................. 11
Reservoir Vent .................................................................................................................................................. 11
Process Coolant ................................................................................................................................................... 12
Electrical Power ................................................................................................................................................... 13
Phase Requirements (if applicable) ................................................................................................................. 13
Optional Signal Inputs/Outputs ............................................................................................................................ 13
Ambient / External Temperature Probe ............................................................................................................ 13
RS-232/RS-485 Serial Output .......................................................................................................................... 13
Remote On / Off Port ........................................................................................................................................ 13
4-20mA Set Point Control ................................................................................................................................. 13
Startup .................................................................................................................................................................. 14
Facility Water Flow (water-cooled units only) ................................................................................................... 14
Filling the Reservoir .......................................................................................................................................... 14
Starting Process Fluid Flow .............................................................................................................................. 14
Normal Operation .................................................................................................................................................. 15
Selecting the Temperature Unit ........................................................................................................................... 15
Displaying and Adjusting the Set Point ................................................................................................................ 15
Selecting the Internal / External Temperature Display ........................................................................................ 15
Displaying and Adjusting the Ambient Track ing Offset ........................................................................................ 16
Displaying and Adjusting the Remote Control Temperature ............................................................................... 16
Selecting the Pressure / Flow Rate Display and Units ........................................................................................ 16
Setting Operational Parameters / Limits .............................................................................................................. 17
Display, Alarm and Error Messages .................................................................................................................... 20
Adjusting the High Pressure Bypass Setting ..................................................................................................... 22
Enabling / Disabling the Local Lockout .............................................................................................................. 22
Over-Temperature Protection ............................................................................................................................... 23
Routine Maintenance............................................................................................................................................. 24
Routine Maintenance ........................................................................................................................................... 24
Condenser, Air Vents and Reusable Filter ....................................................................................................... 24
Inline Strainer ................................................................................................................................................... 24
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Fluid Level ........................................................................................................................................................ 24
Cleaning ........................................................................................................................................................... 24
Temperature Calibration ....................................................................................................................................... 25
Internal Calibration Offset (c1) ............................................................................................................................. 25
External Calibration Offset (c2) ............................................................................................................................ 25
Flow Rate Calibration (Fc) .................................................................................................................................... 26
Fuse Bits (Fb) ......................................................................................................................................................... 26
Troubleshooting .................................................................................................................................................... 27
Diagnostic Mode .................................................................................................................................................. 28
Technical Information ........................................................................................................................................... 29
Controller Specifications ...................................................................................................................................... 29
Performance Specifications ................................................................................................................................. 29
Electrical Specifications ....................................................................................................................................... 30
Pump Performance .............................................................................................................................................. 31
RS-232 / RS-485 Communications ....................................................................................................................... 32
Certificate of Compliance ..................................................................................................................................... 33
Equipment Disposal (WEEE Directive) ................................................................................................................ 33
Service and Technical Support ............................................................................................................................ 33
Replacement Parts ................................................................................................................................................ 34
Pumps .................................................................................................................................................................. 36
Warranty ................................................................................................................................................................. 37
Appendix ................................................................................................................................................................ 38
Flow Schematic - All Models ................................................................................................................................ 38
Electrical Diagrams .............................................................................................................................................. 39
Options ................................................................................................................................................................. 49
General Options Wiring .................................................................................................................................... 49
RS-485 Communications Wiring ...................................................................................................................... 50
DI Control Wiring .............................................................................................................................................. 51
H2 & H3 Option Wiring ..................................................................................................................................... 51
4-20 mA Set Point Control ................................................................................................................................ 52
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Introduction
This symbol alerts you to a wide range of potential dangers. When attached to the unit, consult the operator's manual
.
This symbol advises danger from electricity or electric shock.
This symbol indicates that a hot surface may be present.
This symbol marks information that is particularly important.
This symbol indicates alternating current. These symbols on the Power Switch / Circuit Breaker indicate that they place the main power supply ON / OFF.
This symbol on the Power Key (if present) i ndi cate s that it pla ces the unit in a standby mode. It DOES NOT fully disconnect the unit from the power supply.
WARNING:
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.
DuraChill 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.
General Safety Information
When installed, operated, and maintained according to the directions in this manual and common safety procedures, your Chiller should provide safe and reliable temperature control. Please ensure that all individuals involved in the installation, operation, or maintenance of this Chiller read this manual thoroughly prior to working with the unit.
/
Read all instructions pertaining to safety, set-up, and operation.
Proper operation and maintenance is the user’s responsibility
Safety Recommendations
It is the user’s responsibility to read and understand all instructions and safety 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
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WARNING:
Always operate the unit within the stated temperature and pressure design specification s.
WARNING:
el.
WARNING: Units which use cooling fluid must be properly filled before use and properly drained before moving or service. Allow reservoir fluid to return to ambient temperature before draining. Be sure to follow your organization's procedures and practices regarding the safe lifting and relocation of heavy objects. For items weighing 18 kg or more, safe practice lifting should be performed by at least two people.
WARNING:
formed by fully qualified personnel. Extreme caution is required as
hazards are present when servicing this equip me nt.
WARNING:
CAUTION:
disposing of spent coolant.
WARNING:
Do not plug unit into the electrical outlet until it is ready for startup. Always connect the power cord on this unit to a grounded power outlet. Make certain that the outlet is the
same voltage and frequency as your unit (see identification label). Never operate the unit with a damaged power cord.
Always turn the unit OFF and disconnect mains power before performing any maintenance or service as hazardous voltages exist within cha
WARNING: Make sure the equipment's main power switch is in the OFF position before connecting or disconnecting electrical power from the unit. Follow all applicable electrical and safety codes and procedures when connecting power to the unit. Electrical connections should be made by an authorized electrical installer.
WARNING: Disconnect electrical power before moving the unit. Keep unit upright when moving. Follow your company's procedures and practices regarding the safe lifting and relocation of heavy objects. For items weighing 18 kg or more, safe practice lifting should be performed by at least two people.
All warning labels should be carefully observed. Never remove or obstruct a warning lab
Service should only be per
Do not attempt to operate leaking or damaged equipment.
Be sure to follow all appropriate safety and environmental guidelines when collecting and
ssis components.
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Regulatory and Compliance Testing
Canada USA (60Hz) units
CAN/CSA C22.2 No. 61010-1-12 – Safety Requirements for Electrical Equipment for Measurement, Control and Laboratory Use, Part I: General Requirements.
CAN/CSA C22.2 No. 61010-2-010-04 (R2014) – Safety Requirements for Electrical Equipment for Measurement, Control and Laboratory Use – Part 2-010: Particular Requirements for Laboratory Equipment for the Heating of Materials.
UL Std No. 61010-1 (2012) – Safety Requirements for Electrical Equipment for Measurement, Control and Laboratory Use – Part 1: General Requirements.
UL Std No. 61010-2-010 (2015) – Safety Requirements for Electrical Equipment for Measurement, Control and Laboratory Use – Part 2-010: Particular Requirements for Laboratory Equipment for the Heating of Materials.
CE (50Hz units)
Machinery Directive 2006/42/EC EC Electromagnetic Compatibility Directive 2014/30/EU IEC 61010-1 / EN 61010-1:2010 IEC 61010-2-010 / EN 61010-2-010:2014 IEC 61326:2012 / EN 61326:2013 RoHS Directive 2011/65/EU
Australia/New Zealand (50 Hz)
ACMA – Radiocommunications (Electromagnetic Compatibility) Standard 2008 EN 61326-1:2013
EAC Customs Union (50 Hz)
TP TC 010/2011 On Safety of Machinery and Equipment TP TC 004/2011 On Safety of Low Voltage Equipment TP TC/020/2011 Electromagnetic Compatibility of Technical Equipment
Highly Accelerated Life Test (HALT) and Vibration Tests per ASTM D4169-8 (All units)
Contents
The following items have been inc l ude d with your Chiller:
• Operator’s Manual
• Two sets of Inlet/Outlet Adapters: ½ inch male NPT x ½ inch hose barb and ½ inch male NPT x 5/8 inch hose
barb (select models)
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Controls and Components
Reservoir Cap
Pressure / Flow
Rate Display
Pressure / Flow
Rate Units
Unit / Menu Select Button
Air Filter
Temperature Display
Select / Set Knob
Power Button
Temperature Units
Control Panel
Bypass Valve Access Panel
Air Filter Access
Ambient / External Temperature Tracking Probe Connection (optional)
Control Panel
Front
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Rear – 230V, 240V, and 208-230V Units
Communications Port (optional)
RS-232 Port (optional)
Remote Temperature Probe Port (optional)
Power Switch / Circuit Breaker
Reservoir Vent
(Vent Assembly required
on 5XXX models)
Fluid Inlet (from process)
Fluid Outlet (to process)
Facility Water Outlet (water
-cool models)
Facility Water Inlet
cooled models)
Reservoir Drain
Over-Temperature Protection Adjust (5XXX models only)
Over-Temperature Protection Reset (5XXX models only)
Vent Assembly
(supplied with
5XXX models)
Electrical Connections
Junction Box
Power Switch
(water-
Rear – 380V and 460V Units
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Quick Start
All units:
Connect
Water
A. B. C.
Fill reservoir with coolant Connect electrical power
Mains
Turn Power Switc Breaker ON
Turn Controller ON
Add coolant to reservoir as process lines fill Enter temperature set point
See Installation & Startup f or additional information.
process lines
1
2
3
4
-cooled units:
Connect process lines Connect facility water lines Turn facility water ON
to
h / Circuit
5
6
7
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Installation and Startup
NOTE: The unit may be located at a level below that of the equipment being cooled. As long as the process
remains closed, overflow will not occur when adding cooling fluid to t
he unit's reservoir.
Site Requirements
Ambient Temperature and Relative Humidity
The Chiller is designed fo r indoor installation in ambient temperatures between 16° and 35°C (60° and 95°F); relative humidity should not exceed 80% (non-condensing).
Location
Install the Chiller on a strong, level surface 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. If possible, the unit should be located near a suitable drain to prevent flooding in the event of leaks. Do not place it where corrosive fumes, excessive moisture, excessive dust, or high room temperatures are present.
Position the Chiller as close as possible to the power distribution panel. Avoid voltage drops by using a properly grounded power source wired to meet electrical data plate requirements. The use of an extension cord is not recommended.
Clearance
Allow adequate clearance on the front, sides, and rear of the Chiller for access to connections and components. The front and rear vents of the Chiller must be a minimum of 24 inches (61 cm) away from walls or vertical surfaces so air flow is not restricted.
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External Piping
Facility Water Outlet
Facility Water Inlet
Reservoir Drain
Reservoir Vent
(shown with Vent
Assembly for
5XXX models))
Process Fluid Inlet
Process Fluid Outlet
General Considerations
It is the user’s responsibility to ensure that the tubing and fittings connected to the Chiller are compatible with the fluid, temperature, and pressure being used.
• All external piping, tubing, or hoses should be run full size to limit the potential for external pressure drops.
The use of quick-connect fittings is not recommended, as they can cause substantial pressure drops.
• Materials of construction should be compatible with the fluid being used as well as the temperature and
pressure at which the unit will operate.
• Where applicable, always use a back-up wrench when making piping connections to the Chiller.
• Pressure Ratings – Hoses should be able to withstand the highest pressure that they will encounter (100 psi
/ 6.9 bar).
• Flexible Tubing – Avoid tubing that will expand and increase fluid volume when operating at the desired
pressure.
• Hose Diameter – The fittings on the Chiller’s process fluid lines are female 0.5 in NPT. The facility water fluid
inlets and outlets on water-cooled models are female 0.75 inch NPT.
• Facility Water (water-cooled models only) – Should be clean and well maintained. Ideally, the facility water
should be tested monthly to ensure a pH level between 7.2 and 7.8. Add algaecide if algae growth is present.
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Process Fluid Connections
NOTE:
When Chillers with the standard magnetic drive centrifugal pump are connected to an external
apparatus with a built
-in shutoff, an external bypass loop assembly (Part No. 510-147) may be needed if operating below 20°C (68°F). This bypass assembly continues flow circulation to and from the pump even though the main flow to the external apparatus has been blocked.
WARNING:
On units requiring facility water, those connections must be made by a licensed plumber.
CAUTION: The incoming cooling water pressure should be 20 psi / 1.4 bar minimum and 150 psi / 10.3 bar maximum.
The Chiller has two internally threa ded fittings on the rear of the inst rument housing for the process water connections. Two sets of adapters are supplied with the unit for connecting these fittings to the process piping.
The direction of the flow through the system can be controlled by the way the connections are made. Fluid is drawn into the Chiller through the “Inlet” connection; fluid is pumped out of the Chiller through the “Outlet” connection.
Facility Water Connections
Water-cooled Ch illers have two internally threa ded fittings on the rear of the instrument housing for the facilit y water connections. The c ooling water supply should be con nected to the facility wat er inlet on the Chiller. The facility water outlet on the Chiller should be connected to the appropriate return or drain, as required.
The cooling water supply may be from city tap water or a cooling tower. Th e incoming water pressure should be between 20 and 150 psi / 1.4 and 10.3 bar.
Reservoir Drain
A connection is provided for the reservoir’s gravity drain.
Reservoir Vent
A reservoir vent assembly is provided with Chillers equipped with the heater option to relieve pressure within the reservoir as coolant heats and expands. A connection is provided on the rear of the Chiller for the vent assembly.
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Process Coolant
WARNING: For units that use cooling fluids.
Use only fluids that comply with safety, health, and equipment compatibility requirements. Read the safety data sheet for the fluid being used carefully before use.
CAUTION: DO NOT USE Caustic, corrosive, or flammable liquids
Automotive anti-freeze* Hard tap water* Deionized water with a specific resistance >1 meg ohm Concentrations of acids or bases Solutions with hali des: chlorides, fluorides, bromides , iodides, or sulfur Chlorine bleach Glycerine Syltherm fluids
* At temperatures above 40°C, additives or mineral deposits can adhere to the heater. If deposits are allowed to build up,
the heater may overheat and fail. Higher temperatures and higher concentrations of additives will hasten mineral deposits
WARNING: Operation below 20°C (68°F) requires antifreeze in the circulation fluid. Do not use automotive antifreeze as the additives m
ay be harmful to the Chiller's wetted parts.
Suitable Fluids
The Chiller can accommodate a variety of coolant fluids (water, glycol mixtures, etc). For most applications above 20°C (68°F), distilled water is satisfactory. For operation below 20°C (68°F), the Chiller must be protected with an antifreeze solution. Ethylene glycol (laboratory grade) and water in a 50/50 mixture is satisfactory from +20° to -15°C (68° to 5°F). Select a fluid that is compatible with the Chiller’s wetted parts (brass, bronze, stainless steel, EPDM rubber, nylon, PVC).
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Electrical Power
WARNING:
Do not plug unit into the electrical outlet until it is ready for startup. Always connect the power cord on this unit to a grounded power outl
et. Make certain that the outlet is the same voltage and frequency as your unit (see identification label). Never operate the unit with a damaged power cord.
Always turn the unit OFF and disconnect mains power before performing any maintenance or service a
s
hazardous voltages exist within chassis components.
WARNING:
Make sure the equipment's main power switch is in the OFF position before connecting or disconnecting electrical power from the unit. Follow all applicable electrical and safety codes and procedures when connecting power to the unit. Electrical connections should be made by an authorized electrical installer.
WARNING:
DO NOT apply power until the unit is ready for Startup.
NOTE: In order for the Chiller to properly recognize the presence of the external temperature probe, the
probe must be connected to the unit before power is applied..
Connect the power cord (if) supplied with the Chiller to an appropriate electrical outlet.
Phase Requirements (if applicable)
For 3-phase units, be sure to connect in proper sequence, ie.: L1, L2, and L3. These Chillers are designed with a
junction box on the rear of the unit to which you can connect the electrical power supply conduit. Be sure to
provide suitable conduit strain relief and grounding.
3-phase units are equipped with a phase monitor that prevents startup if phase sequence is incorrect. The Chiller
will turn OFF in the event of a loss of one phase and/or prevent operation if there is a voltage mismatch between
any two phases greater than 8%.
Optional Signal Inputs/Outputs
Ambient / External Temperature Probe
Allows control of the cooling fluid temperature using an external temperature measurement (ambient
room/machine temperature or process temperature). A 9-pin connector is provided for connecting the
ambient/external tracking probe.
RS-232 / RS-485 Serial Output
Allows remote control the Chiller and/or the output of temperature readings to an external auxiliary device. The
maximum communications distance for Chillers equipped with the RS232 option is 50 feet (15 meters). The
maximum distance for units equipped with the RS485 option is 4000 feet (1200 meters). A 9-pin D-connector is
provided for this connection.
Remote On / Off Port
Allows the connection of a remote On/Off switch or other remote control device to the Chiller. A 15-pin D-
connector is provided on the rear of the instrument enclosure for this connection.
4-20mA Set Point Control
Allows set point changes using a customer supplied current value. A 15-pin D-connector or 8-pin circular
connector is provided for this connection.
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Startup
NOTE:
When adding fluid to the unit for the first time, prime the pump by pressing the Power Button
to turn
power
ON, letting the Chiller run for 3 seconds, and the pressing the P
ower Button again to turn power OFF.
Repeat this ON and OFF procedure three times.
Facility Water Flow (water-cooled units only)
1. Open the valves to the facility water supply and return.
2. Check for leaks.
Filling the Reservoir
1. Remove the reservoir cap located on the top of the Chiller and, using a funnel, add fluid until it is approximately 2 inches (5.1 cm) below top of reservoir.
2. Once the fluid level is about 2 inches (5.1 cm) below the top of the reservoir, remove the funnel but do not replace the cap at this time.
Starting Process Fluid Flow
1. Place the circuit breaker located on the rear panel of the Chiller to the ON position. The display on the front
panel will respond by showing standby (....). If there is no response, check that the unit is connected to
working electrical power and that circuit breaker on the rear of the Chiller is in the ON position.
2. Press the Power Button on the front panel. The system startup sequence will begin and proceed as follows:
• The pump will turn on and fluid will begin circulating through the system.
• The set point temperature will appear briefly on the Temperature Display; after a few seconds, it will be
replaced by the actual fluid temperature.
• 15 to 20 seconds after power up, the compressor will begin operating.
3. Check for leaks.
4. With the pump running, the reservoir’s fluid level will drop as the process and/or process cooling lines fill with fluid. Slowly add fluid to the reservoir until the liquid level remains stable.
5. Replace the reservoir cap.
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Normal Operation
NOTE:
The Chiller incorporates a special "lockout" feature that can be enabled to prevent unauthorized o
r
accidental set point and other operational changes. This feature is described in detail under
"Enabling and
Disabling the Local Lockout."
It should not be enabled until all operational paramet ers hav e been set.
IMPORTANT: All user settings, except baud rate and calibration offset, return to the original factory defaults
when the temperature unit is changed. The Chiller's temperature set point and various alarm settings should be reset to desired values.
NOTE: Temperature set point cannot be changed when the local lockout is enabled or remote temperature control is installed and enabled. It allows the user to check or continuously display either the Chiller's internal outlet fluid temperature or the external ambient/process temperature.
NOTE:
This section applies only wh
en the ambient tracking probe or remote temperature control is installed and enabled. It allows the user to check or continuously display either the Chiller's internal outlet fluid temperature or the external ambient/process temperature.
NOTE: P1 or P2 will remain on the pressure/flow rate display until the Units/Menu Select button is pressed
and released. The displayed temperature will revert to the default condition (internal temperature for the ambient probe, external temperature for the remote temperature control probe).
Selecting the Temperature Unit (°C or °F)
The LEDs adjacent to the Temperature Display indicate the unit (°C or °F) used for Temperature Displays. To change from °C to °F or vice versa, proceed as follows:
To change to °F — Place the Circuit Breaker/Power Switch on the rear of the instrument in the OFF position. Press and hold the Units/Menu Select Button while returning the Circuit Breaker/Power Switch to the ON position.
To change to °C — Place the Circuit Breaker/Power Switch on the rear of the instrument in the OFF position. Press and hold the Power Button on the front panel while returning the Circuit Breaker/Power Switch to the ON position.
Displaying and Adjusting the Set Point
Press the Select/Set Knob on the front panel. The current set point temperature will be displayed, and the decimal point at the bottom right of the display will flash, indicating that the temperature can be changed.
Rotate the Select/Set Knob until the desired set point temperature is displayed. The setting is accepted after the Select/Set Knob is pressed a second time or automatically after a few seconds of inactivity.
Selecting the Internal / External Temperature Display
When the ambient tracking probe is selected (AtC), the Chiller normally displays the internal outlet fluid temperature. To display the external ambient temperature, press and release the Units/Menu Select Button until P2 appears on the Pressure/Flow Rate Display.
When the remote temperature control probe is selected (rPC), the Chiller normally displays the external process temperature. To display the internal outlet fluid temperature, press and release the Units/Menu Select Button until P1 appears on the Pressure/Flow Rate Display.
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Displaying and Adjusting the Ambient Tracking Offset
NOTE:
Ambient tracking is an optional function that may or m
ay not be available on your Chiller. It permits
you to control fluid temperature based on room or machine temperature plus or minus a user
-adjustable
offset temperature.
NOTE:
Remote temperature control is an optional function that m
ay or may not be available on your Chiller.
It permits you to control cooling based on the temperature of the external process.
NOTE:
Metric pressure reading output is displayed in kPA and must be multiplied by 100 for Pa.
NOTE:
The flow rate readout is intended as a reference only. If accurate flow readings are required, an
external flow meter is recommended.
When the optional ambient tracking probe is installed and enabled (AtC), the ambient tracking offset rather than the set point temperature is displayed when the Select/Set Knob on the front panel is pressed.
To change the displayed offset value, rotate the Select/Set Knob unt il the des ired of fset value is displayed. An offset value from -5.0°C to +5.0°C (-9.0° to +9.0°F) may be entered. The setting is accepted after the Select/Set Knob is pressed a second time or automatically after a few seconds of inactivity.
Displaying and Adjusting the Remote Control Temperature
When the optional remote control external probe is installed and enabled (rP), the external temperature set point is displayed when the Select/Set Knob on the front panel is pressed.
To change the external temperature set point, press and then rotate the Select/Set Knob until the desired set point temperature is displayed. The setting is accepted after the Select/Set Knob is pressed a second time or automatically after a few seconds of inactivity.
Selecting the Pressure / Flow Rate Display and Units
The Chiller can set to display either fluid pressure (in PSI or kPa) or flow rate (in GPM or LPM). Pressing the Units/Menu Select Button briefly toggles through the available selections.
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Setting Operational Parameters / Limits
NOTE:
Some parameters listed may not be included in your version of software.
NOTE:
The ranges and default settings shown are for standard models. Range
s and default settings for your
unit may differ depending on the options selected.
Menu Item
Description
Choices / Ranges
Default Setting
High Temperature Limit — Limits the maximum allowable
set point temperature. Audio and visual alarm indicators are activated when the measured fluid temperature reaches the HL temperature setting.
NOTE: EHL will appear on the display if the High Limit value
is set
below the cu rrent set point.
Units without heater
option (6xxx ) =
+20 to 40 ºC
(68 to 104ºF)
Units with heater option
(5xxxx)
= +20 to 95 ºC
(68 to 203ºF)
6xxx = 40 ºC 5xxx = 95 ºC
Low Temperature Limit — Limits the minimum allowable set point temperature. Audio and visual alarm indicators are activated when the measured fluid temperature reaches
the
LL
temperature setting.
NOTE: ELL will appear on the display if the Low Limit value
is set above the
current set point.
High Ambient Temperature Limit — Maximum ambient temperature limit. Displayed and settable
only in ºC.
Should
the ambient temperature rise above the
HA
value, the audio and visual alarms will activate and the compressor, heater, fan, and pump will turn
OFF.
NOTE:
Chiller
’s rated cooling capacity is dependent on an
ambient temperature of 20°C (68
ºF). Performance will decrease as the ambient temperature rises. Continuous operation at ambient temperatures above 40ºC (104ºF) is not recommended.
Various operational parameters are user-adjustable. They are accessed by pressing and holding the Units/Menu Button until HL appears on the Pressure/Flow Rate Display. Pressing and releasing the Units/Menu Button once HL appears allows you to scroll through the various parameters; rotating the Select/Set Knob allows you to change the displayed setting. You can accept the displayed value by either pressing the Select/Set Knob or allowing the display to timeout.
Operational parameter limit alarms will shut down the compressor, fan, pump and heaters. Some temperature values are only displayed and settable in ºC
HL
LL
HA
0.0 to +15 ºC (32 to 59 ºF)
+30 to 50ºC 40 ºC
5.0ºC
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Menu Item
Description
Choices / Ranges
Default Setting
FP
Maximum Fluid Pressure — Maximum allowable fluid
pressure; settable in either PSI or kPa.
Should the fluid pressure rise above the maximum fluid pressure value, the audio and visual alarms will activate and the compressor, heater, fan, and pump will turn
OFF.
NOTE:
The Chiller also incorporates a built in pressure regulated bypass valve. It will maintain a max imum outl et pressure by diverting flow of the process fluid to the reservoir. The bypass valve may be adjusted by the customer.
CAUTION:
Maximum operating pressure for the Chiller
is
100 PSI
/
6.9 bar. Different pumps have different maximum
operating pressures.
(display value x 100)
80 PSI
5.5 x 100 = 550 kPa
Minimum Flow Rate — Minimum allowable flow rate; settable in either GPM or LPM.
Should the
fluid flow rate drop below the minimum value, the audio and visual alarms will activate, and the compressor, heater, fan, and pump will turn OFF.
Auto-Refrigeration Set Point — The upper temperature at which the refrigeration system will activate; displayed and settable in °C only. There will be no refrigeration or cooling at set points above the AF setting.
Maximum External / Internal Temperature Differential
(optional)
— Esta
blishes the cooling/heating rate when the
remote temperature control probe is installed and enabled.
Ambient Tracking / Remote Probe (optional) AtC
— Ambient tracking probe enabled.
Chiller controls fluid temperature based on room or machine temperature (wherever the ambient tracking probe is located) plus or minus a user
-set offset (±5.0°C / ±9.0°F).
rPC
— Remote probe enabled. Chiller controls fluid temperature based on the process fluid temperature at an external location.
nO
— Ambient tracking / remote probe disabled.
nRP — Ambient tracking probe not installed.
Dependent on option and
software installed.
C1 / C2
Calibration Offset — Allows adjustment of the displayed
temperature to match that of an independent traceable standa
rd; displayed and settable in °C only.
C1
— Internal calibration offset
C2 — External calibration offset
Flow Rate Calibration
— Allows adjustment of the
displayed flow rate to match that of a known standard.
Note value here for
reference/replacement of
PCB or flow sensor
20 to 100 PSI 13 to 680 kPa
FL
AF
Sd
rP
0 and 1.5 to 3 GPM
0 and 6 to 11 LPM
+20° to 40°C 35°C
4° to 20°C 5°C
1.5 GPM
6.0 LPM
nAP
±2.9°C 0.0°C
Fc
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Varies
Menu Item
Description
Choices / Ranges
Default Setting
Current Control (optional) — Allows setting of the set point
temperature via a 4
-20 mA analog signal.
yES
— Enables current control.
NO
— Disables current control.
Communications Baud Rate
—
Selects the baud rate for
serial (RS232/RS485) communication.
24 (2400), 48 (4800),
96 (9600) or 192 (19200)
The current Fuse Bits (Fb) setting appears after the PC setting and can be viewed, but not changed. To change Fuse Bits (Fb) operational parameters, electrical power must be turned OFF and a special key stroke combination entered. See
Fuse
Bits (Fb)
for detailed instructions.
Fuse Bits
Logic
State
h00
h01
h02
h05
h06
Remote ON / OFF
dry contact
Closed
Off
On
Off
On
N/A
Open
On
Off
On
Off
24 VDC Remote
Control Voltage
24 VDC
Off
Off
On
Off
N/A
On
0 VDC
On
On
Off
On
Off
Water Level Float
Switch
Open
OK
OK
OK
Low
Low
Low
Closed
Low
Low
Low
OK
OK
OK
CC
PC
Fb
Yes or No No
9600
Input
N/A
h04
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Display, Alarm and Error Messages
Message Code
Low fluid level warning —
units with
float
switch
Fluid flow too low warning
units with flow
switch (
no
reservoir option).
Warning
sound once every 8 seconds for 5 occurrences. If
has not
been Add fluid to the reservoir.
Hi temperature
Warning /
(as measured on the Control PCB) alternates between EHA and the fluid temperature; the unit continues normal operation. If the ambient temperature stays over 5°C above the high ambient limit for more than 5 seconds, Fault 16 occurs.
Lower ambient temperature or raise
temperature limit.
High
perature
alarm
Warning / Alarm
igh temperature limit value. The display alternates between EHL and the fluid temperature; the temperature stays above the Fault 03 occurs.
Lower temperature set point or incr
Low temperature alarm
Warning / Alarm
The temperature set point is lower than the low temperature limit value. The display alternates between ELL and the fluid temperature; the unit continues normal operation. temperature stays below the occurs
Increase temperature set point or decrease low limit value.
No fluid flow and no fluid pressu
Warning / Alarm — LO is displayed alternately with H2O and fluid
temperature if the
the fluid flow is less than the low flow limit. alarm will occur and the compressor, heater, turned OFF.
Local Lo ckout
Normal
Disabling the Local Lockout) is enabled. Appears momentarily when Select/Set
Cancel Local
Normal
Disabling the Local Lockout
momentarily when Local Lockout status is changed from enabled (LLO) to disabled.
External remote control active
Normal
(optional).
Fluid level in reservoir low
Warning / Alarm
. Indicates that the fluid level has fallen below the lower float. warning/alarm appears, there will Chiller will turn OFF
When certain conditions are detected, a message code flashes on the display and the local audio alarm sounds. Depending on the nature of the condition, power to various systems components is removed. When the condition is rectified, push the front panel Power Button or turn the circuit breaker OFF then ON to clear the fault or error.
Description Action Required
EFL
EHA
EHL
ELL
fluid level
.
—
PO - no pump –
gh ambient
limit tem
warning
limit
/ Alarm — Fluid level or flow switch is open. Alarm will
problem
corrected after 40 seconds, Fault 05 occurs.
Alarm - The ambient temperature
is higher than the set ambient limit. The display
high ambient
— The temperature set point is higher than the h
unit continues normal operation. If the fluid
HL value for more than 25 seconds,
ease high limit value.
—
If the fluid
LL value for 25 seconds, Fault 02
.
LO-
H2O
LLO
CAn
EC
EF2
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Lockout
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— Indicates that Local Lockout feature (see Enabling /
— Indicates the Local Lockout feature (see Enabling /
— Chiller is in Standby mode until remotely activated
re is no fluid pressure and If both conditions last for 3-4 minutes, Fault 07
fan, and pump are
Knob is pressed to view/change set point value.
) has been disabled. Appears
— Units with Dual Float Option only
When the EF2
be a short delay and then the
.
If a fault should occur, the left display will show Ft, and the right display will show one of the fault codes shown
Low limit temperature alarm
Alarm — Process fluid temperature is below the low temperature
limit value for more than 25 seconds. Compressor, heater, and fan are turned
To clear the fault, turn the unit off then on using the
ower
Button, and decrease the LL value.
High limit temperature alarm
Alarm — Process fluid temperature is above the high temperature
limit value for more than 25 seconds. Compressor, heater, and fan are turned
OFF; pump remains ON.
To clear the fault, turn the unit off then on usi
ng the front panel P
ower
Button, and increase the HL value.
Over-temperature alarm
Alarm — Process fluid temperature is above Chiller’s factory set high
temperature safety cutoff. Heater, compressor, and fan turned OFF; pump remains
Lower process temperature.
Low liquid level alarm
(select models only)
Delayed Alarm — Activated when the liquid level in the reservoir falls below an acceptable level for over 40 seconds. Compressor, heater, fan, and pump are turned
Add fluid to reservoir.
Low flow alarm
Alarm — Fl ow rate has dropped below minimum flow rate setting for
more than 10 seconds. Compressor, heater, fan, and pump are turned
Correct cause of low flow rate or decrease minimum flow rate setting.
High pressure alarm
Alarm — Fluid outlet pressure has exceeded high-pressure limit
value for over 10 seconds. Compressor, heater, fan, and pump are turned
Decrease outlet pressure by removing blockage or increas e high pressure limit value.
Internal software fault
Fault — One or more settings are out of range. Compressor, heater,
fan, and pump are turned
OFF.
Default unit to °C or °F; if fault persists, c
ontact service
representative.
Electronic power component fault (Triac)
Fault — Heater triac has failed for more than 10 seconds.
Compressor, heater, fan, and pump are turned
OFF.
Contact service representative.
Internal probe fault
Fault — Main temperature control probe has failed for more than 4
seconds. Compressor Contact service representative.
External temperature probe fault
(select models only)
Fault — External temperature control probe has failed for more than 4 seconds. Compressor, heater, fan, and pump are turned
Replace ambient tracking probe or operate instrument using internal temperature probe. Contact service representative if fault persists.
Input
4-20 mA Option — Input for temperature set point too high or too
low. Correct input or switch to standard control.
below.
Fault Code
Description Action Required
02
03
04
05
07
08
OFF; pump remains ON.
front panel P
ON.
OFF.
OFF. Note: Disabled during first 2 minutes of operation.
OFF.
-
09
10
11
12
18
– Out of Range
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, heater, fan, and pump are turned OFF.
OFF.
Adjusting the High Pressure Bypass Setting
WARNING:
hazards are present when servicing this equip me nt.
IMPORTANT: The Local Lockout feature does not prevent set point changes entered via the RS232 interface or 4
Locknut
Chillers with a positive displacement or turbine pump incorporate an automatic safety to maintain outlet pressure below a valve-regulated pressure. This valve is adjustable and is located inside the Chiller housing.
Service should only be performed by fully qualified personnel. Extreme caution is required as
To access the high-pressure bypass valve, remove the access panel on the top of the unit (rear left). The high-pressure bypass is adjusted as follows:
1. Set the low flow rate alarm value to zero (see Setting Operationa l Parameters, Minim um Flow Rate). This will
prevent the unit from activating the flow alarm while you are adjusting the maximum pressure setting.
2. Com pletely block the Chiller’s outlet flow. This should cause the outlet pressure to rise.
3. Set the Pressure/Flow Rate Display to read either PSI or kPa.
4. Rotate the handle on the pressure valve until the desired maximum
pressure setting is shown on the Pressure/Flow Rate Display.
5. Secure the Locknut.
6. Reset the flow alarm value to the previous setting.
7. Return the Pressure/Flow Rate Display to the previous setting.
8. Replace the access panel.
Enabling / Disabling the Local Lockout
This feature is used to prevent unauthorized or accidental changes to set point and other operational values. When enabled, the values for the following functions can be displayed, but not changed:
• Temperature unit
• Temperature set point
• Ambient tracking offset
• Pressure / flow rate units
To enable the local lockout, press and hold the Select/Set Knob until LLO is displayed. Once enabled, LLO will appear momentarily when the Select/Set Knob is pressed to display the set point.
To disable the local lockout, press and hold the Select/Set Knob until CAn appears momentarily as local lockout status changes from enabled (LLO) to disabled.
-20 mA inputs.
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Over-Temperature Protection
IMPORTANT:
range of the OTP cutout on 5XXX model Chillers is approximately 60° to 110°C. However,
the OTP cutout should never be set above the factory
OTP Reset Button
OTP Cutout
Adjustment Screw
6XXX Chillers — The OTP for 6XXX model Chillers is fixed at a cutout temperature of 60°C. The OTP will auto- reset once the fluid temperature drops below the cutout temperature.
5XXX Chillers — The OTP for 5XXX model Chillers with the heater option is adjustable and disconnects power to the heater at a factory-set temperature of 95°C. The OTP is reset by pressing the red button located on the rear panel of the Chiller. If required, the cutout temperature may be adjusted using the OTP cutout temperature adjustment screw located to the left of the red reset button. To change the OTP cutout temperature, rotate the adjustment screw clockwise until it stops, bring the fluid temperature to the desired cutout temperature, and then rotate the adjustment screw counterclockwise until the OTP opens. 95°C is the maximum cutout temperature.
OTP Adjustment Screw and Reset — 5XXX Chillers only
The
-set temperature of 95°C.
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Routine Maintenance
NOTE:
On units equipped with the heat
er option, check fluid level when operating at maximum temperature
and allow for fluid expansion. Use of a venting assembly (see
“Controls and Components”
) is recommended.
Inline Strainer
Filter Cap
Fitting
20 Mesh
Stainless Steel
Screen
Routine Maintenance
The Chiller is designed to require a minimum of periodic maintenance.
Condenser, Air Vents and Reusable Filter
The condenser, the air vents, and reusable filter should be kept free of dust and dirt. They should be checked on a regular basis and cleaned as required.
The reusable filter is accessed from either the left or right side of the unit. Use a mild detergent and water solution to wash off any accumulated dust and dirt. Rinse and dry thoroughly before reinstalling.
Inline Strainer
An inline strainer with 2 0 mesh stainless steel sc reen is located on the inlet to the heat exchanger. To acc ess,
remove the Chiller’s top co ver (attached at the rear of the unit with two screws). Remove the threaded cap, pull
the screen out of the fitting, rinse off any particulate material, and reinstall. Be sure to check for leaks after reinstalling.
Fluid Level
The fluid level should be periodically checked to determine if the fluid level needs to be topped off. Generally, fluid should be added whenever the level in the reservoir is 2 inches (5.1 cm) below the top of the reservoir.
Cleaning
Only mild detergents and water or an approved cleaner should be used on the painted and stainless steel surfaces of the Chiller. Do not allow cleaning liquids or sprays to enter the Controller vents.
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Temperature Calibration
IMPORTANT: To prevent the operator from accidentally changing the calibration offset, a special keystoke
sequence is required to access this function.
NOTE: Calibration offset values are always set and displayed in °C.
1
0.0
IMPORTANT: To prevent the operator from accidentally changing the calibration offset, a special keystroke sequence is required to access this function.
NOTE:
Calibration offset values are always set and displayed in °C.
At times, there may be a minor temperature difference between the Chiller’s displayed temperature and the actual temperature as determined by a certified temperature measurement device. There may also be situations where you want the displayed temperature to match a particular value to have standardization between different instruments. These adjustments can be performed using the Chiller’s internal and/or external temperature calibration offset functions.
C
Internal Calibration Offset (
This menu item allows you to adjust the Chiller’s internal temperature reading to match that of a traceable standard. It allows you to offset the displayed temperature value by as much as ±2.9°C.
1. Press and hold the Units/Menu Button until HL appears on the display.
2. Press and release the Units/Menu Button until rP appears on the display.
3. Press and hold the Units/Menu Button.
4. While holding the Units/Menu Button, press and release the Select/Set Knob.
1)
5. When CL1 appears on the Temperature Readout, release the Units/Menu Butt on. The current calibration offset value will appear on the T emperature Readout and alternate with the fluid temperature read ing (enabling you to simultaneously adjust the offset and see the effect on the temperature).
6. Rotate the Select/Set Knob until the desired calibrat io n offset is disp layed. Press the Select/Se t Knob or simply allow the display to time out to accept the displayed value.
C
External Calibration Offset (C2)
This menu item allows you to adjust the Chiller’s external temperature reading to match that of a traceable
standard. It allows you to offset the displayed temperature value by as much as ±2.9°C. It appears only if the external temperature probe is installed.
1. Press and hold the Units/Menu Button until HL appears on the display.
C
2. Press and release the Units/Menu Button until
1 appears on the display.
3. Press and hold the Units/Menu Button.
4. While holding the Units/Menu Button, press and release the Select/Set Knob.
5. When CL2 appears on the Temperature Readout, release the Units/Menu Button. The current calibration offset value will appear on the Temperature Readout and alternate with the fluid temp erature reading (enabling you to simultaneously adjust the offset and see the effect on the temperature).
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6. Rotate the Select/Set Knob until the desired calibration offset is displayed. Press the Select/Set Knob or
2
0.0
NOTE:
Your Chiller's flow rate is calibrated at the factory at the nominal flow rate for the installed pump.
Further adju
stment is not necessary.
Fc 0.0
Fb h00
simply allow the display to time out to accept the displayed value.
C
Flow Rate Calibration (Fc)
This menu item allows you to adjust the flow rate display to match that of a known standard.
1. Press and hold the Units/Menu Button until HL appears on the display.
2. Press and release the Units/Menu Button until the second FL appears (LPM LED will be lit – Fc will be the next parameter).
3. Press and hold the Units/Menu Button.
4. While holding the Units/Menu Butto n, pr ess and release the Select/Set Knob.
5. When CAL appears on the Temperature Readout, release the Units/Menu Button.
6. Rotate the Select/Set Knob until the desired offset is displayed. Press the Select/Set Knob or simply allow the display to time out to accept the displayed value.
Fuse Bits (Fb)
This menu item allows you to select the logic settings for remote control and the water level float switch. To set fuse bits, proceed as follows:
1. Turn electrical power OFF at the rear of the unit.
2. Press and hold the Select/Set Knob and Power Button simultaneously.
3. While holding the Se lec t/ Se t Kn ob and Po wer Butto n, turn electrical power ON at the rear of the unit.
4. Fb will appear on the Pressure/Flow Rate Display; h followed by two digits will appear on the Temperature Display.
5. Rotate the Select/Set Knob to the desired setting (h00, h01, h02, h04, h05, or h06).
6. Press and release the Select/Set Knob or simply allow the display to time out to accept the displayed setting.
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Troubleshooting
Many problems can be resolved by restoring the factory defaults. If this solves the problem, be careful when restoring your operational settings in order not to repeat the problem.
To restore the factory default settings:
1. Place the Power Switch / Circuit Breaker on the rear of the unit in the OFF position.
2. Press and hold the Power Button on the front panel while returning the Power Switch / Circuit Breaker to the
WARNING:
hazards are present when servicing this equip me nt.
Problem
Possible Causes
Corrective Action
Unit does not run (digital displays blank)
No power to unit
Check that the electrical cord or wiring is secure and connected to an operating electrical
Check that Power Switch / Circuit Breaker on rear of unit is ON.
Unit does not run (three decimal points appear on
, two decim Pressure/Flow Rate Display)
Unit in Standby mode
Press Power Button on front panel. No fluid circulation
Insufficient fluid in reservoir Blockage in circulating system Pump is not operating
Add fluid to reservoir. Remove blockage. Replace pump.
Insufficient circulation
Fluid viscosity too high External tubing diameter too
small Restrictions in fluid lines Low line voltage
Replace with lower viscosity fluid. Replace with larger diameter tubing.
Check and correct as required. Check and correct as required.
Unit does not cool or cooling is insufficient
Dust build up on air filter or condenser
Blocked air ventilation screens Excessive heat load
Ambient air temperature too high
Low or high line voltage Faulty temperature sensor
Clean air filter and/or condenser as required.
Remove blockages as required. Check that heat load does not exceed capacity of Chiller;
correct as required. Decrease ambient air temperature.
Check and correct as required. Check the compressor upper, evaporator inlet and
evaporator outlet temperature sensor readings (see
“Diagnostic Mode”). If any of these temperature readings
is -50°C, the sensor needs to be replaced.
Unit does not heat
OTP has tripped due to Insufficient fluid in reservoir
Add fluid to reservoir and reset OTP.
Fault code 10 on display
Extreme electrical line interference
Triac failure
Plug unit into another power source. If problem persists, triac has failed.
Replace triac or triac driver as required.
ON position.
Service should only be performed by fully qualified personnel. Extreme caution is required as
Temperature Display
al points on
source.
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Problem
Possible Causes
Corrective Action
Fa
Internal probe failure
Contact
Fault code 12 on display
Loose external probe connection
Faulty external temperature probe
Check and correct as required.
Replace as required.
NOTE:
using internal probe until
problem is corrected.
NOTE:
The Chiller must be set to display temperature in °C in order to access the diagnostic mode.
NOTE:
Diagnostic items are display values only; they cannot be changed.
Menu Item
Description
Ambient temperature at front panel
External control
Percent of Line voltage
Chiller
type (model)
Fuse bits (remote control voltage, contact closures, etc.)
External probe temperature and “
---“, displayed when external probe is not installed
03 (variable numeric value)
Fluid flow rate or pressure; Temperature Display
shows current fluid temperature
ult code 11 on display
service representative.
Chiller may be operated
Diagnostic Mode
The Chiller incorporates a Diagnostic mode, which displays important operational information that can aid in troubleshooting. To access the Diagnostic mode, place the Circuit Breaker/Power Switch in the OFF position and then return it to the ON position while pressing and holding the Select/Set Knob. The diagnostic menu appears on the Pressure/Flow Rate Display; the current value for the diagnostic item appears on the Temperature Readout.
At
EC
Li
Ct
Fb
EP
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Technical Information
Te
±0.1°C
Temperature Stability
±0.5°C (±0.9°F)
Temperature Units
°C or °F
Pressure Units
PSI or kPa
Pressure Display Resolution
1 PSI / 0.1 kPa
Flow Rate Units
GPM or LPM
Flow Rate Display Resolution
0.1 GPM / 1 LPM
Model
Air-Cooled
58XX & 68SS Series
Water-Cooled
59XX & 69XX Series
Compressor
Nominal HP
Temperature Range (without heater option)
°F °C
Temperature Ra (with heater option)
°F °C
Temperature Stability
°F °C
Cooling Capacity
Tons Watts BTU/hour
Nominal Evaporator Flow
US GPM
Refrigerant
Pressure
PSIG
Pump
HP
Fan(s)
HP
Condenser Discharge Air Flow
CFM
Water Condenser Flow – Tower Water
US GPM
Water Condenser Connections
Inches
Process Connections (inlet / outlet)
Inches
Reservoir Tank Capacity
US Gallons
Dimensions (L x W x H)
Inches cm
Shipping Weight
Pounds kg
Controller Specifications
mperature Set Point Resolution
Performance Specifications
nge
1
2
3
3
1/3 1/6 N/A
1. Capacity of air-cooled units based on 68°F (20°C) entering air and 68°F (20°C) leaving water; capacity of water-cooled units based on 85°F (29°C) entering water.
2. Chiller flow rate based on 2.4 US GPM ton (0.54m
Environmental Conditions Indoor use only Maximum Altitude: 2000 meters Operating Ambient: 5° to 35°C Relative Humidity: 80% for temperatures to 30°C Installation Category: II Pollution Degree: 2
1.5 41° to 95°F
5° to 35°C
41° to 194°F
5° to 90°C
±0.9°F ±0.5°C
1.48
5200
17,732
1.8
6328
21,600
3.72 4.3 R134A
60
1070 N/A
N/A 5.4
N/A 0.75
0.5 (liters) 3.5 (13.25)
30.5 x 19 x 26”
78 x 48 x 66 cm
340 154
3
/hr/ton).
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Electrical Specifications
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Pump for 1-1/2 HP Chillers
1.5 HP Pumps
0
20
40
60
80
100
120
0 2 4 6 8
10
12
14
GPM
PSI
P4 3.5 GPM Positive Displacement
P6 4 GPM Positive Displacement
P9 2.33 GPM Positive Displacement
M5 Mag Drive Centrifugal
T2 1/3 HP Turbine
T5-T6-T7-T8 3/4 HP Turbine
T9-TD-TE 1 HP Turbine
S1 Speck Pump 7.5 GPM
S1
1 HP
3/4 HP
T2
M5
P9 P4 P6
Specifications subject to change without notice.
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RS-232 / RS-485 Communications
RS-232
RS-485
Pin # 2
Transmit (Tx)
Pin # 3
DAT (+) on “B”
Pin # 3
Receive (Rx)
Pin # 5
signal ground
Pin # 5
signal ground
Pin # 9
DAT (-) on “A”
Command
Format
Set command echo
SEi[CR]
Echo: i = 1 No Echo: i = 0
![CR]
Set
SOi[CR]
On: i = 1 Off: i = 0
![CR]
Set set point
SSxxx[CR]
x = ASCII digit
![CR]
Read set point temperature
RS[CR]
![CR]
Read temperature
RT[CR]
![CR]
Read temperature units
RU[CR]
C or F
C[CR] or F[CR]
Read status
RW[CR]
1 = Run 0 = Standby
1[CR] or 0[CR]
Read pressure in PSI
RP[CR]
![CR]
Read pressure in kPa
RK[CR]
![CR]
Read flow in GPM
RG[CR]
![CR]
Read flow in LPM
RL[CR]
![CR]
Read remote control voltage
RC[CR]
![CR]
Read remote temperature probe
RR[CR]
![CR]
Read ambient temperature on PCB
RA[CR]
![CR]
Read fault status
RF[CR]
![CR]
Read line voltage
RV[CR]
![CR]
Read internal temperature
R1[CR]
![CR]
Read external temperature
R2[CR]
![CR]
Serial Connector — A 9-pin D-connector (optional) is provided on the back panel of the Chiller for RS232 / RS485 data communication. A serial cable that uses only the following pins should be used to connect the Chiller to the computer:
RS-232 / RS-485 Protocol — The controller uses the following RS-232 / RS-485 protocol:
Data bits — 8 Parity — none Stop bits — 1 Flow control — none Baud rate — selectable (Chiller and PC baud rates must match).
Communications Comm ands — Comm ands must be entered in the exact f ormat shown. Do not s end a [LF] (line feed) after the [CR] (carriage return). Be sure to follow character case exactly. A question m ark (?) indicates that the Chiller could not execute the command (either because it was in an improper format or the values were outside the allowable range). A response followed by an exclamation point (!) indicates that a command was executed correctly. A response must be received from the Chiller before another command can be sent. All responses are terminated with a single [CR].
Command Description
On / Off
Values Return Message
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Certificate of Compliance
Temperature P ro file
0.00
5.00
10.00
15.00
20.00
25.00
30.00
35.00
40.00
0:00:00 0:04:04 0:08:09 0:12:40 0:16:45 0:20:50 0:24:55 0:29:00 0:33:0
T ime (hh:mm:ss)
1
2
3
4
All Chillers are tested after assembly to ensure that the product meets or exceeds published mechanical and safety specifications as well as your s atisfaction. The Certif icate of Compliance is inclu ded with the Chiller. T he following graph explains the steps involved in a typical test.
1. Raise fluid temperature.
2. Measure cooling performance.
3. Apply heat load to Chiller to simulate real application conditions. The heat load applied is based on the Chiller’s cooling capacity.
4. Measure temperature stability.
Equipment Disposal (WEEE Directive)
or
This equipment is marked with the crossed out wheeled bin symbol to indicate it 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.
Service and Technical Support
If your unit fails to operate properly, contact the supplier from whom the unit was purchased. Have the model, serial number, and voltage information from the back panel label along with a summary of the problem available.
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Replacement Parts
Description
Controller PCB
NOTE:
note the software version. You
can obtain the software version by pressing and holding the Power
oller
while the unit is in “Standby”. For our standard software the left display will read “T3” and the right display will read “
software version, your model number and serial number will be
Varies with software
RTD Temperature Sensor
Remote / Ambient Tracking Probe, 10’ cable, DB9 Female Plug
Remote / Ambient Tracking Probe, 25’ cable, DB9 Female Plug
Remote / Ambient Tracking Probe, 50’ cable, DB9 Female Plug
Fluid Pressure Sensor, Standard
Fluid Pressure Sensor, SS, DI units
VLV, BR, BYP, ½, 45
KIT Rotor, 6 Pole Flow Indicator
Switch, Circuit Breaker,
Flow Sensor, Hall Effect, Honeywell
Float Switch, Water Level, Single Float @ 7.0”
Float Switch, Water Level, Dual Float, @ 6.8/8.0”
Float Switch, Water level, Dual Float, @ 4.6/9.3” (NC contacts)
Compressor,1.5HP,COP
Compressor,
Compressor,
Compressor, 1.5H
Motor, Fan, 230V, Emerson # 050
Motor, Fan, 380
Heater Cartridge, 240V, 1000W
Heater Cartridge, 240V, 1000W (5xxx units)
Heater Cartridge,
Heater Cartridge, 4
Heater Cartridge, 480V, 3000W
Solid State Relay, 50 Amp, Crydom HA6050
Solid State Relay, 25 Amp, 48
Contactor, ABB A9
Contactor, ABB A26
Contactor, ABB DP60C2P
Capacitor, Start, Compressor, 145
Part Number
When replacing the Controller PCB, it is important to
003” or software version T3-003. If you are unable to obtain the
200-430-KIT
-100#, Insulated 750-175-KIT
30 Amp, 1PH 215-818
Button on the contr
required.
options
060101 060105 060110
750-381-KIT
750-384-KIT
330-571-KIT
330-087
235-061
235-064
235-055
#CS18K6E-PFV-255 750-876
2.0HP,COP #CS18K6E-PFJ-255 750-877
2.0HP,COP#CS18K6E-TFD-255 750-878 P, COP #CS18K6E-TF5-255 750-883
-0265-00 215-519
-460V, Emerson # 950-0265- 0 1 215-629 (6xxx units) 215-459
215-903
240V, 2500W 215-564
80V, 1000W 215-654
215-644
-10 (for Heaters) 200-343
-600V, 3-32CV (Compressor) 200-580
-30-10-36 215-468
-30-10-36 215-674
-2 215-802
-174MFD, 250V, COP#914-000-607 750-336
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Description
Part Number
Capacitor, Run, Compressor, 35MFD,370V, COP#914
Ca
Relay, Compressor, COP#040
PCB, 4
High Pressure Control, Penn#P100CC
Compressor Pressure Regulator
Valve,
Filter Dryer, SP#C
Air Filter, Condenser
ORLY,ABB, TF42
ORLY,ABB, TF42
ORLY,ABB, TF42
ORLY,ABB, TF42
ORLY,ABB, TF42
ORLY,ABB, TF42
ORLY,ABB, TF42
ORLY,ABB, TF42
ORLY,ABB,
CNTOR,ABB,AF09
CNTOR,ABB,AF12
CNTOR,ABB,AF16
CNTOR,ABB,AF26
CNTOR,ABB,AF40
CNTOR,ABB,AF09Z
CNTOR,ABB,AF16Z
RELAY, 50A/600V CRYDOM HA6050
PHASE MONITOR,208
CNTOR,ABB,AF09Z
SUPPRESSOR,TRANSIENT, RK#RCS3G
SUPPRESSOR,TRANSIENT, RK#RCS2G
PCB ASM, 1.5HP, 230V, BLUE LIGHT, HEAVY
ORLY,ABB, TF42
ORLY,ABB, TF42
ORLY,ABB, TF42
Operator’s Manual (on CD 110
-0037-11 (60HZ) 750-337
pacitor, Run, Compressor, 45MFD,370V, COP#914-0037-18 (50HZ) 750-414
-0166-15, COP#040-0166-15 750-338
-20mA Set Point Control 500-342
-9C, 275/175 215-473
Valve, SP#CRO-T-6-30/11 0- 5/8ODF 750-766
Solenoid, Refrigeration, Liquid and Hot Gas Bypass, PK#DS1100,240VAC
-053-S, 3/8ODF 750-075 750-387
-1.3, 1.0-1.3A 200-566
-1.7, 1.3-1.7A 200-567
-2.3, 1.7-2.3A 200-568
-3.1, 2.3-3.1A 200-569
-4.2, 3.1-4.2A 200-570
-5.7, 4.2-5.7A 200-571
-7.6, 5.7-7.6A 200-572
-10, 7.6-10.0A 200-573
TF42-1.0, 0.74-1.0 200-574
-30-10-13 215-905
-30-10-13 215-906
-30-10-13 215-907
-30-00-13 215-908
-30-00-13 215-909
750-179
-30-10-21 215-914
-30-10-21 215-921
-10 200-343
-480V,50-60HZ 215-851
-30-10-21 215-914
-6V 215-919
-6 215-653 500-451-D
-1.3, 1.0-1.3A 200-566
-1.7, 1.3-1.7A 200-567
-2.3, 1.7-2.3A 200-568
-925) 110-392
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Pumps
Description
P4
106
P6
280
P9
218
M5
M6
S1
S3
T2
T5
T6
T7
T8
T9
TD
TE
TF
TH
Part Number
– Positive Displacement, Rotary Vane, Bronze, 3.5 GPM, 240V/1PH/50-60HZ
– Positive Displacement, Rotary Vane, Stainless Steel 4 GPM, 240V/1PH/50-60HZ
– Positive Displacement, Rotary Vane, Bronze, 2.33 GPM,240V/1PH/50-60HZ
– Mag-Drive Centrifugal Pump, 240V/1PH/50-60HZ (6xxx) 525-552
– Mag-Drive Centrifugal Pump, 240V/1PH/50-60Hz (5xxx) 525-332 – Speck Centrifugal, Stainless Steel, 7.5 GPM, 240V/1PH/50-60HZ 215-306 – Speck Centrifugal, Stainless Steel, 7.5 GPM, 240V/480V/3PH/50-60Hz 215-884
– 1/3HP Turbine, Bronze 3.5 GPM, 240V/1PH/50-60HZ 215-305 – 3/4HP Turbine, Bronze, 240V/1PH/50-60HZ 215-499 – 3/4HP Turbine, Stainless Steel, 240V/ 1PH/50-60HZ 215-474 – 3/4HP Turbine, Stainless Steel, 208-230V/ 3PH/50-6 0HZ 215-475 – 3/4HP Turbine, Bronze, 208-230V/3PH/50-60HZ 215-487 – 1HP Turbine, Stainless Steel, 208-230V/3PH/50-60HZ 215-568
– 1HP Turbine, Bronze, 208-230V/3PH/50-60HZ 215-651 – 1HP Turbine, Bronze, 240V/1PH/50-60HZ 215-655 – 1HP Turbine, Bronze, 380/3/60Hz 215-873
– 2HP Turbine, Bronze, 208/230/1/60Hz 215-336
Pump – 215­Motor – 215-217
Pump – 215­Motor – 215-217
Pump – 215­Motor – 215-217
Pump assemblies include motor unless listed separately.
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Warranty
NOTE:
The warranty applies only to the original end us
er and cannot be transferred or sold to another end
user without written consent from the manufacturer.
The manufacturer’s warranty is one year for parts and labor and two years for parts. Please contact your supplier for additional warranty details and service contract information.
The manufacturer agrees to correct for the original user of this product, e ither by repair, or at the manufacturer's election, by replacement, any defect that develops after delivery of this product for the warranty period(s) stated above. 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 a replacement unit is sent,
the defective unit must be returned to the manufacturer within 30 days of receipt of the replacement unit. If the defective unit is not received within 30 days, the manufacturer reserves the right to bill for the replacement unit.
If this product requires service, contact the manufacturer/supplier's office for instructions. If 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.
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Appendix
Flow Schematic - All Models
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Electrical Diagram – 208-230V / 1PH / 50-60Hz Models without heater option
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Electrical Diagram – 208-230V / 1PH / 50-60Hz Models with heater option
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Electrical Diagram – 208-230V / 3PH / 50-60Hz Models without heater option
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Electrical Diagram – 208-230V / 3PH / 50-60Hz Models with heater option
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Electrical Diagram – 208-230V / 3PH / 50-60Hz Models with heater option and 4-20ma set point option
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Electrical Diagram – 380V / 3PH / 60Hz Models without heater option
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Electrical Diagram – 380V / 3PH / 60Hz Models with heater option and 4-20ma set point option
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Electrical Diagram – 380-460V / 3PH / 50-60Hz Models without heater option
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Electrical Diagram – 380-460V / 3PH / 50-60Hz Models with heater option and 4-20ma set point option
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Electrical Diagram – 380-460V / 3PH / 50-60Hz Models with heater option
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Options
Pin 3 to Pin 11
Pin 5 to Pin 11
Power Off
X Standby
X
Alarm X
Running X
General Options Wiring
Status Alarm (STA): Relay is energized when Chiller is running normally. Relay is de-energized when a fault condition
is detected, the unit is placed in Standby, or the unit's power is off.
Remote ON/OFF: RCV = Chiller turns OFF when 12-24V AC or DC signal is applied.
RCS = Chillers turns OFF when contacts are closed.
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RS-485 Communications Wiring
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DI Control Wiring
H2 & H3 Option Wiring
H2 = 24 VDC H3 = 12 VDC
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4-20 mA Set Point Control
NOTE:
Two versions are available. If the model number of your Chiller contains anNin the 11
th
digit (e.g., 6860T56A26
ND), it provides 4-20mA set point co
ntrol over a temperature range of 5° to
90°C; if the 11
th
digit is an K, the 4-20mA control range is 4° to 40°C
This feature is optional and may not appear in your version of the software.
Go to menu item “CC” and set to “YES”.
If current input is outside of the range of the 4–20 mA, “Ft 18” will be displayed.
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