PolyScience DA500, DA750, DA1000, DW500 Operator's Manual

Operator’s Manual
DuraChill™ Air- and Water-Cooled Chillers
5, 7.5 and 10 HP
Table of Contents
Introduction............................................................................................................................................................ 4
Standard and Optional Features ......................................................................................................................... 4
Standard Features ........................................................................................................................................... 4
Optional Features............................................................................................................................................. 4
General Safety Information.................................................................................................................................. 5
Safety Recommendations.................................................................................................................................... 6
Regulatory Compliance and Testing ................................................................................................................... 7
Unpacking............................................................................................................................................................ 7
Controls and Components...................................................................................................................................8
Control System .................................................................................................................................................... 8
Control Panel ................................................................................................................................................... 8
Power Switch / Disconnect .............................................................................................................................. 8
Temperature Probe .......................................................................................................................................... 8
Flow Sensor ..................................................................................................................................................... 8
Flow Switch ...................................................................................................................................................... 8
Fluid Pressure Sensor ..................................................................................................................................... 8
Refrigerant Pressure Switches ........................................................................................................................ 8
Fan Cycling Switch........................................................................................................................................... 9
Reservoir Float Switch (Optional) .................................................................................................................... 9
Fluid Circulation System ...................................................................................................................................... 9
Evaporator........................................................................................................................................................ 9
Reservoir Tank................................................................................................................................................. 9
Sight Glass or Level Indicator .......................................................................................................................... 9
Pump................................................................................................................................................................ 9
Full Flow Bypass .............................................................................................................................................. 9
Y-Strainer ......................................................................................................................................................... 9
External Bypass / Shutoff Valves..................................................................................................................... 9
Process Side Stream Filter System (Optional) ................................................................................................ 9
Cooling System.................................................................................................................................................... 9
Common Cooling System Components........................................................................................................... 9
Evaporator...................................................................................................................................................... 9
Compressor.................................................................................................................................................... 9
Filter Dryer...................................................................................................................................................... 9
Sight Glass ..................................................................................................................................................... 9
Thermostatic Expansion Valve (TXV) ............................................................................................................ 9
Hot Gas Bypass Solendoid Valve ................................................................................................................ 10
Refrigerant Safety Relief Valve .................................................................................................................... 10
Air-Cooled Chillers (DA Models) .................................................................................................................... 10
Condenser.................................................................................................................................................... 10
Condensing Fan........................................................................................................................................... 10
Water-Cooled Chillers (DW Models).............................................................................................................. 10
Brazed Plate Heat Exchanger / Condenser ................................................................................................. 10
Condensing Water Regulating Valve ........................................................................................................... 10
Receiver ....................................................................................................................................................... 10
Component Identification................................................................................................................................... 11
Front - All Models ........................................................................................................................................... 11
5 HP and 7.5 HP Chillers - Rear .................................................................................................................... 11
10 HP Chillers - Rear ..................................................................................................................................... 12
Installation and Startup ...................................................................................................................................... 13
Site Requirements ............................................................................................................................................. 13
Ambient Temperature and Relative Humidity ................................................................................................ 13
Location.......................................................................................................................................................... 13
Clearance....................................................................................................................................................... 13
Electrical Power ................................................................................................................................................. 14
Signal Inputs/Outputs ........................................................................................................................................ 15
Remote On / Off ............................................................................................................................................. 15
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Alarm Output .................................................................................................................................................. 15
RS-232/RS-485 Serial Output........................................................................................................................ 15
External Piping................................................................................................................................................... 16
General Considerations ................................................................................................................................. 16
Process Fluid Connections ............................................................................................................................ 16
Facility Water Connections ............................................................................................................................ 16
Reservoir Drain .............................................................................................................................................. 16
Reservoir Vent ............................................................................................................................................... 16
Full Flow Bypass ............................................................................................................................................ 17
Process Coolant ................................................................................................................................................ 18
Suitable Fluids................................................................................................................................................ 18
Startup ............................................................................................................................................................... 19
Facility Water Flow (water-cooled units only) ................................................................................................ 19
Filling the Reservoir ....................................................................................................................................... 19
Starting Process Fluid Flow ........................................................................................................................... 20
Normal Operation................................................................................................................................................ 21
Power On........................................................................................................................................................... 21
Temperature Unit (°C or °F) Selection / Factory Default Reset ........................................................................ 21
Adjusting the Set Point Temperature................................................................................................................. 22
Selecting the Pressure / Flow Rate Display and Units ...................................................................................... 22
Displaying Internal (P1) and External (P2) Probe Temperatures...................................................................... 22
Setting Operational Parameters / Limits............................................................................................................ 22
High Temperature Limit (HL) ......................................................................................................................... 25
Low Temperature Limit (LL)........................................................................................................................... 25
High Ambient Temperature Limit (HA)........................................................................................................... 26
Maximum Fluid Pressure (FP) ....................................................................................................................... 26
Minimum Flow Rate (FL)................................................................................................................................ 26
Lower Band (Lb)............................................................................................................................................. 27
Upper Band (Ub) ............................................................................................................................................ 27
Remote Probe (rP)......................................................................................................................................... 27
Calibration Offset (C1 / C2 / C3) .................................................................................................................... 27
Compressor Delay (Cd) ................................................................................................................................. 28
Flow Rate Calibration (Fc) ............................................................................................................................. 28
Coolant Density (dS)...................................................................................................................................... 28
Specific Heat (Sh) .......................................................................................................................................... 28
Current Control (CC)...................................................................................................................................... 28
Communications Baud Rate (PC).................................................................................................................. 29
Low Ambient Temperature Limit (LA) ............................................................................................................ 29
Password (Pd)................................................................................................................................................ 29
HGB Valve Delay (td)..................................................................................................................................... 29
Fuse Bits (Fb)................................................................................................................................................. 29
Enabling / Disabling the Local Lockout.............................................................................................................. 30
Display, Alarm and Error Messages..................................................................................................................31
Automatic Restart from Alarm Mode ................................................................................................................. 33
Routine Maintenance..........................................................................................................................................34
Recommended Routine Maintenance Schedule ............................................................................................... 34
Reservoir Coolant Level .................................................................................................................................... 34
Coolant Freeze Protection ................................................................................................................................. 34
Inline Strainer..................................................................................................................................................... 34
Air Filters............................................................................................................................................................ 35
Troubleshooting.................................................................................................................................................. 36
Troubleshooting Chart ....................................................................................................................................... 36
Compressor Overload Fault (Ft20).................................................................................................................... 37
Low Pressure Sensor..................................................................................................................................... 37
High Pressure Sensor.................................................................................................................................... 37
Technical Information......................................................................................................................................... 38
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Chiller Specifications ......................................................................................................................................... 38
Air-Cooled Chillers (DA500, DA750, DA1000) .............................................................................................. 38
Water-Cooled Chillers (DW500) .................................................................................................................... 38
Electrical Specifications ..................................................................................................................................... 39
DA500 Chillers ............................................................................................................................................... 39
DW500 Chillers .............................................................................................................................................. 40
DA750 Chillers ............................................................................................................................................... 41
DA1000 Chillers ............................................................................................................................................. 41
Pump Performance............................................................................................................................................ 42
RS-232 Serial Communications (RS-485 Option) ............................................................................................. 43
Equipment Disposal (WEEE Directive) ............................................................................................................. 44
Service and Technical Support.......................................................................................................................... 44
PolyScience Chiller Fluids ................................................................................................................................. 45
Warranty............................................................................................................................................................... 45
Appendix.............................................................................................................................................................. 46
Flow Schematic – Air-Cooled Chillers ............................................................................................................... 46
Flow Schematic - Water-Cooled Chillers........................................................................................................... 47
Wiring Diagram - 5 HP and 7.5 HP Air-Cooled Chillers .................................................................................... 48
Wiring Diagram - 10 HP Air-Cooled Chillers...................................................................................................... 49
Wiring Diagram - 5 HP Water-Cooled Chillers .................................................................................................. 50
4-20 mA Set Point Control................................................................................................................................. 51
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Introduction
The PolyScience line of 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.
Standard and Optional Features
DuraChill Chillers offer exceptional performance, reliability, and operational simplicity. Available in both air- and water-cooled models, these robust self-contained Chillers are engineered to provide accurate temperature control in a broad range of process cooling applications.
These powerful Chillers can be configured with a wide variety of standard and optional features, including:
Standard Features
Process temperature range: 32° to 86°F (0° to 30°C)
Ambient temperature range: 60° to 104°F (16° to 40°C)
Temperature stability: ±2.0°F (±1.1°C)
High efficiency vertical air exhaust
Accurate microprocessor control with digital LED readout
Pump protection by means of a Full Flow Bypass Valve
Copeland Scroll compressor
Compressor protection through high and low refrigerant pressure cuto
RS-232 communications interface
Reservoir sight glass
Remote On / Off control (dry con
Dry contact status alarm output
Power phase monitor on 3-phase units
Heavy-duty locking casters for easy maneuverability
Stainless steel c
®
uts
r- and under-temperature alarms • Process protection provided by ove
tact)
entrifugal pump (1 HP on 5 and 7.5 HP units; 2 HP on 10 HP units)
O t
p ional Features
Other centrifugal and turbine pump
s
RS-485 communications interface
Remote On / Off control
(24 VDC)
Process shutoff valves
External bypass valve
Stainless steel reservoir
Heaters
Feet to replace casters
Reservoir level float switch
Side stream filter assemblies
External inlet / outlet filter assemblies
Deionized compatible process plumbing
Configuration Data Sheet showing how your DuraChill Chiller is equipped is included with the manual if
A applicable (see inside front cover).
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General Safety Information
When installed, operated, and maintained according to the directions in this manual and common safety procedures, your DuraChill 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.
This symbol alerts you to wide range of potential dangers.
This symbol advises you of 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.
This symbol indicates a protective conductor terminal. Only connect the unit to a power socket with earth (ground) contact (PE – protective earth). The power supply connector plug serves as a safe disconnecting
device from the line and must always be easily accessible.
These symbols on the Power Switch / Disconnect indicate that they place the main power supply ON / OFF.
This symbol on the Power Button indicates that it places the unit in a standby mode. It DOES NOT fully
disconnect the unit from the power supply.
Read all instructions pertaining to safety, set-up, and operation.
Proper operation and maintenance is the user’s responsibility.
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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.
WARNING: All warning labels should be carefully observed. Never remove or obstruct a warning label.
WARNING: Installation, operation, or maintenance of this equipment should be performed in strict
accordance with the instructions outlined in this manual. Failure to follow those instructions may
increase the risk of personal injury, damage the equipment, and/or void the warranty.
WARNING: Be sure to remove power from the equipment, reclaim the refrigeration charge, and relieve
any residual pressure before cutting into the refrigeration system.
WARNING: Do not attempt to operate leaking or damaged equipment.
WARNING: Service should only be performed by fully qualified personnel. Extreme caution is required
as hazards are present when servicing this equipment.
WARNING: Do not attempt to override the power interlock switch or any other safety feature on this
equipment.
WARNING: Disconnect electrical power before moving unit. Keep unit upright when moving. Always
follow your company’s procedures and practices regarding safe lifting and relocation of heavy objects.
WARNING: Make sure the equipment’s main power switch is in the OFF position before connecting or
disconnecting power. 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: This equipment must be properly filled with cooling fluid before use and properly drained
before moving or service.
WARNING: 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: Always operate this equipment within the stated design specifications.
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Regulatory Compliance and Testing
CSA UL (5 HP 60Hz units)
CAN/CSA C22.2 No. 61010-1-04 — Safety Requirements for Electrical Equipment for Measurement, Control and Laboratory Use, Part I: General Requirements.
CAN/CSA C22.2 No. 61010-010-04 — 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 (2
nd
edition) — Electrical Equipment for Laboratory Use, Part I: General Requirements.
CE (All 50Hz units)
EC Low Voltage Directive 2006/95/EC EC Electromagnetic Compatibility Directive 2004/108/EC IEC 61010-1-2001 IEC 61010-2-10 : 2005 IEC 61326-1:2005
Unpacking
Your Chiller is shipped in a special container. Retain the container and all packing materials until the unit is completely assembled and working properly. Set up and run the unit immediately to confirm proper operation. 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.
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Controls and Components
Your DuraChill Chiller consists of three basic sub-systems:
Control
Fluid circulation
Cooling
This section describes these sub-systems in detail and includes information on the available options. Please note that your Chiller may or may not be equipped with all the components discussed.
Control System
Control Panel — Temperature set point, temperature units, and other operating parameters are set via the
Control Panel. Operating information is displayed on a local digital readout.
Pressure / Flow
Rate Display
Units / Menu
Select Button
Pressure / Flow Rate Unit
Temperature
Display
Power Switch / Disconnect — The main power switch is located on the front door of the Chiller. This switch
also functions as a power disconnect when access to the unit’s components and terminal blocks is required; the access door cannot be opened until the Power Switch / Disconnect is placed in the OFF position.
Temperature Unit
Select / Set Knob
Power Button
NOTE: Loss of Power – In the event that power is lost while the Chiller is operating, the unit will
automatically resume operation when the power is restored. If the unit was in Standby mode when power is lost, it will power up in Standby mode. The above is also true if power is removed via the Power Switch / Disconnect.
Temperature Probe — An internal RTD is used to measure fluid temperature downstream of the pump. Its
reading is displayed on the Control Panel’s LED temperature display.
Flow Sensor — Monitors process fluid flow. If the flow rate is less than the user-settable alarm value, power to
the pump, compressor, and fan is removed and an alarm message displayed on the Control Panel’s LED readout.
Flow Switch — Requires a minimum of ~4 gpm (15.1 lpm) to close. If the flow rate is too low, the switch will
open and power to the pump, compressor, and fan removed; an alarm message will also be displayed on the Control Panel’s LED readout.
Fluid Pressure Sensor — Measures fluid pressure at the pump outlet. If the fluid pressure exceeds the user-
settable alarm value, power to the pump, compressor, and fan is removed and an alarm message displayed on the Control Panel’s LED readout.
Refrigerant Pressure Switches — When activated, these switches remove power to the pump, compressor,
and fan; an alarm message is also displayed on the Control Panel’s LED readout.
The Low Pressure Switch opens if the refrigerant pressure falls below 10 psi (0.7 bar) and closes if the pressure is above 30 psi (2.1 bar). The Low Pressure Switch will auto-reset.
The High Pressure Switch opens if the refrigerant pressure exceeds 630 psi (43.4 bar). The High
Pressure Switch must be manually reset (see Troubleshooting, Compressor Overload Fault).
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Fan Cycling Switch — This switch control fan operation. The fan turns ON when the discharge pressure of the
refrigerant exceeds 400 psi (27.8 bar) and remains running until the pressure falls below 300 psi (20.7 bar).
NOTE: 10 HP Chillers have two fans. One fan turns ON with the compressor and runs continuously as long
as the compressor is ON; operation of the second fan is based on refrigerant pressure as described above.
Reservoir Float Switch (Optional) — Measures liquid level in the Chiller’s reservoir. If the fluid level drops too
low, power to the pump, compressor, and fan is removed and an alarm message displayed on the Control Panel’s LED readout.
Fluid Circulation System
This sub-system governs fluid flow through the Chiller.
Evaporator — Serves as the heat exchanger between the refrigeration and fluid flow systems. Cools fluid
before it returns to process.
Reservoir Tank — This polyethylene tank is used to maintain stable temperature control and an adequate
reservoir of fluid for the system. It may be equipped with an optional float switch that monitors fluid level and activates an alarm. A stainless steel reservoir is available as an option.
Sight Glass or Level Indicator — This indicator serves as a convenient means of checking the liquid level
within the Reservoir Tank. The sight glass is located on the rear panel.
Pump — Used to pump fluid from the Reservoir Tank to the process and back to the Chiller. A variety of pumps
are available for operation at different pressures, flow rates, and distances from the Chiller to the process.
Full Flow Bypass — Allows the maximum operating pressure to be regulated and protects the Pump in the
event that process piping becomes restricted or clogged. Diverts flow from the process line back to the Evaporator and Reservoir.
Y-Strainer — Located on the inlet to the Chiller. Incorporates a cleanable 20 mesh (841 micron) stainless steel
screen to remove large particulate matter from the process fluid.
External Bypass / Shutoff Valves — Allows the unit to be operated independent of the process during the
servicing of process equipment and/or process lines. Can also be used to fine-tune process pressure and flow rate.
Process Side-Stream Filter System (Optional) — Consists of a 50 micro filter and ball valve connected
between the Chiller inlet and outlet. It is used to filter particulate matter from a portion of the process fluid flow.
Cooling System
NOTE: The Condenser on DuraChill Chillers is either air-cooled or water-cooled.
Common Cooling System Components
The following components are common to both air-cooled (DA models) and water-cooled (DW models) DuraChill Chillers:
Evaporator — Serves as the heat exchanger between the refrigeration and fluid flow systems. Removes heat
from the process fluid before it is returned to the process equipment.
Compressor — The Chiller incorporates a 5 to 10 HP Copeland Scroll compressor. The Compressor is
protected from overloads through high and low pressure cutouts.
Filter Dryer
— Removes residual particulate matter and moisture from the refrigeration system. The Filter Dryer
must be replaced whenever the sealed refrigeration lines are opened for service.
Sight Glass — Used to observe refrigerant fluid flow to the Evaporator. Thermostatic Expansion Valve (TXV) — Controls refrigerant superheat at the outlet of the Evaporator to
prevent liquid from returning to the Compressor.
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Hot Gas Bypass Solenoid Valve — Injects refrigerant vapor into the Evaporator to help maintain a constant
temperature when the temperature of the process fluid falls below the temperature set point. Under low- and no­load conditions, temperature continues to fall until it reaches the “Lb” lower band and shuts the Compressor OFF.
Refrigerant Safety Relief Valve — This is an automatic safety used to vent refrigeration gas if it exceeds 650
psi (44.8 bar).
Air-Cooled Chillers (DA Models)
The following components are specific to air-cooled DuraChill Chillers:
Condenser — The Compressor pumps vapor into the Condenser at high pressure. As the surrounding air is
cooler than the hot vapor, heat energy passes into the air from the condenser coils.
Condensing Fan — a 1 HP fan (two fans on 10 HP units) that draws air over the condenser coils to cool
refrigerant gas. The standard fan cycles ON and OFF based on refrigerant pressure (ON at 400 psi / 27.6 bar; OFF at 300 psi / 20.7 bar). The second fan on 10 HP units runs whenever the Compressor is ON.
Water-Cooled Chillers (DW Models)
Brazed-Plate Heat Exchanger / Condenser — Serves as the heat exchanger between the refrigeration system
and the facility water supplied by the customer. Removes heat from the refrigerant.
Condensing Water Regulating Valve — This valve regulates the facility water flow to maintain optimal
discharge pressure (approximately 250 psi / 17.2 bar) for the heat exchange in the Condenser. It increases flow to decrease pressure and decreases flow to increase pressure.
Receiver — The main purpose of the Receiver is to temporarily store refrigerant (in its liquid state) that is not
required when load conditions are low. The Receiver also provides a constant supply of liquid to the Thermostatic Expansion Valve (TXV).
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Component Identification
Front – All Models
Control Panel
5 HP and 7.5 HP Chillers – Rear
Power Switch / Disconnect
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10 HP Chillers – Rear
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Installation and Startup
WARNING: Be sure all power is OFF before proceeding.
Site Requirements
Ambient Temperature and Relative Humidity
The Chiller is designed for indoor installation in ambient temperatures between 60° and 104°F (16° and 40°C); relative humidity should not exceed 80% (non-condensing).
Location
The Chiller should be installed on a strong, level surface capable of supporting 1050 lbs. / 476.3 kg (5 and 7.5 HP units) or 1500 lbs. / 680.1 kg (10 HP units).
It should be located as close to possible to the process requiring cooling and installed no closer than 4 feet (1.4 meters) to a heat-generating source, such as heating pipes, boilers, etc. If possible, the Chiller 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.
For ease of positioning and maneuverability, the Chiller is supplied with casters. The front wheels can be locked to keep the Chiller in place while in use.
To help prevent voltage drops, 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.
NOTE: The Chiller 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 the Chiller reservoir.
Clearance
Adequate clearance should be allowed 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.
Overall Dimensions
Model Length Width Height
DA500 56 in. (142.2 cm) 34.5 in. (88 cm) 67 in. (170.2 cm)
DW500 56 in. (142.2 cm) 34.5 in. (88 cm) 32.1 in. (81.6 cm)
DA750 56 in. (142.2 cm) 34.5 in. (88 cm) 67 in. (170.2 cm)
DA1000 77 in. (195.6 cm) 34.5 in. (88 cm) 68.2 in. (173.2 cm)
110-279 13
Electrical Power
WARNING: Make sure the 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:
Make certain that the electrical supply is the same voltage and frequency as your unit (see identification label).
Make sure electrical connections comply with all applicable electrical codes. Ground the Chiller in accordance with NEC Article 250. Operating voltage must be within 10% of the data plate rating. Phase imbalance must be below 5%.
WARNING: DO NOT apply power to the Chiller until the unit is ready for Startup
CAUTION: DO NOT apply power to the Chiller until the Reservoir has been filled. When Controller power
is turned ON, the pump automatically begins pumping. If the Reservoir has not been filled, the pump could
be damaged.
The Chiller is equipped with a phase monitor that prevents startup if phase sequence is incorrect. It will also turn the Chiller OFF in the event of a loss of one phase and/or prevent Chiller operation if there is a voltage mismatch between any two phases greater than 8%. Be sure to connect electrical lines in proper sequence, i.e.: L1, L2, and L3.
There is 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.
WARNING: DO NOT remove the ground wire while diagnosing any power supply problems.
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Signal Inputs/Outputs
Remote On / Off and Alarm Output
Remote On / Off
This allows the operator to turn the Chiller ON and OFF using a remote dry contact. The Chiller is ON when the contact is open; it is OFF when the contact is closed. A 10-ft (3 m) cord with 5-pin mating plug is provided.
Alarm Output
This allows the operator to connect a remote alarm device to the Chiller. The alarm output consists of normally open (NO) and normally closed (NC) contacts which are switched whenever an alarm, fault, or error condition is detected or when the Chiller is OFF. A 10-ft (3 m) cord with 5-pin mating plug is provided.
RS-232 Serial Communication (RS-485 Option)
This allows the operator to remotely control the Chiller and/or output temperature readings to an external recorder or other auxiliary device. A 9-pin D-connector is provided on the rear of the instrument enclosure for this connection.
The maximum communications distance for Chillers equipped with RS-232 is 50 feet (15 meters); the maximum distance for units equipped with the RS-485 option is 4000 feet (1200 meters).
See the Technical Information section for serial communications protocol and commands.
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