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DuraChill
Operating Manual
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Operating Manual
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PolyScience DuraChill Operating Manual

User Guide
Refrigerated Recirculating Chillers
110-969 August 21 2019
General Safety Information .....................................................................................................................................5
Safety Recommendations ...................................................................................................................................5
Unpacking Your Chiller ...........................................................................................................................................6
Regulatory and Compliance Testing .......................................................................................................................6
Package Contents ...................................................................................................................................................6
Controls and Components ......................................................................................................................................7
Front View — Air-Cooled Models ........................................................................................................................7
Rear View — Air-Cooled Models .........................................................................................................................7
Quick Start ..............................................................................................................................................................8
Site Requirements...................................................................................................................................................9
Ambient Temperature and Relative Humidity .....................................................................................................9
Location ...............................................................................................................................................................9
Clearance ............................................................................................................................................................9
Electrical Power ...................................................................................................................................................9
Optional Signal Inputs/Outputs ............................................................................................................................ 10
External Control / Ambient Tracking Temperature Probe ................................................................................ 10
RS232 Serial Output ........................................................................................................................................ 10
Remote I/O Port................................................................................................................................................ 10
USB Serial / TMC Output ................................................................................................................................. 10
Plumbing .............................................................................................................................................................. 10
Process Piping.................................................................................................................................................. 10
Drain ................................................................................................................................................................. 10
External Water Filter ......................................................................................................................................... 10
Closed System or Cooling Coil Setup .............................................................................................................. 11
Open Bath System Setup ................................................................................................................................. 11
Process Coolant ................................................................................................................................................... 12
Suitable Fluids .................................................................................................................................................. 12
Recommended Fluids ...................................................................................................................................... 13
Fluid Compatibility Table .................................................................................................................................. 13
Filling the Reservoir .......................................................................................................................................... 13
Electrical Power ................................................................................................................................................ 13
Starting Process Fluid Flow .............................................................................................................................. 14
Standby Screen .................................................................................................................................................... 15
Home Screen (Default Operation with Internal Probe Only) ................................................................................ 15
Liquid Level Sensor .......................................................................................................................................... 16
Setting a Temperature ...................................................................................................................................... 16
Access Settings and Other Functions in the Menu .............................................................................................. 17
Selecting the Temperature Unit (°C or °F) ........................................................................................................... 17
List of Chiller Menu Parameters ....................................................................................................................... 18
Adjusting the High Pressure Bypass Setting ....................................................................................................... 21
Routine Maintenance ........................................................................................................................................... 22
Condenser, Air Vents and Reusable Filter ....................................................................................................... 22
Air Filter Access................................................................................................................................................ 22
Passive Filter .................................................................................................................................................... 22
Dynamic Filter................................................................................................................................................... 23
UV Anti-Growth Light (Optional) ....................................................................................................................... 24
Fluid Level Sensor ............................................................................................................................................ 24
Fluid Properties ................................................................................................................................................ 24
Draining the fluid............................................................................................................................................... 24
Temperature Calibration ................................................................................................................................... 24
Troubleshooting ................................................................................................................................................... 26
Restoring Factory Default Settings................................................................................................................... 26
Recommended Troubleshooting Procedures ................................................................................................... 27
Display, Alarm, and Error Messages ................................................................................................................ 29
Diagnostic Mode ............................................................................................................................................... 31
General Specifications (all Chillers) ..................................................................................................................... 32
Pump Performance .............................................................................................................................................. 32
Performance Specifications — 60Hz Chillers ...................................................................................................... 33
Air-Cooled 1/4-HP, 1/3-HP and 1/2-HP Chillers ............................................................................................... 33
Air-Cooled 1-HP Chillers .................................................................................................................................. 34
Performance Specifications — 50Hz Chillers ...................................................................................................... 35
Air-Cooled 1/4-HP, 1/3-HP and 1/2-HP Chillers ............................................................................................... 35
Air-Cooled 1/4-HP, 1/3-HP and 1/2-HP Chillers ............................................................................................... 35
Air-Cooled 1-HP Chillers .................................................................................................................................. 36
Diagrams and Schematics ................................................................................................................................... 37
Electrical Wiring Diagram – High Voltage ........................................................................................................ 37
Electrical Wiring Diagram – Low Voltage ......................................................................................................... 38
Process Flow Schematic (Air Cooled Chiller) .................................................................................................. 39
Replacement Parts............................................................................................................................................... 40
Communications .................................................................................................................................................. 43
Connector Pinout .............................................................................................................................................. 43
Serial Port Protocol Definitions and Commands .............................................................................................. 44
Certificate of Compliance ..................................................................................................................................... 47
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Introduction
Your Recirculating Chiller provides cooling power for demanding applications and serves as an economical alternative to tap water cooling systems. Extremely easy to use and maintain, it combines technological innovation with precise temperature control to deliver reliable heat removal for a wide variety of applications.
Here are some of the features that make your Chiller so user-friendly:
• Microprocessor-based temperature controller
• Large, easy to read touch screen display (temperature readout in °C or °F)
• Multi-Language Interface
• Touch keypad temperature set point adjustment
• Cool Command™ modulated refrigeration system for enhanced temperature stability and extended
compressor life
• WhisperCool
decrease energy consumption
• Chillers with standard reservoir configuration feature continuous level sensing for pump protection
• Diagnostic Self-Test routine allows operators to test the Chiller's performance against a factory baseline
• USB Port for data logging
• Optional pumping configurations include positive displacement and turbine pump
• UV Anti-Growth Light (featured on certain models) inhibits biological growth in the Chiller's process fluid
• Self-Cleaning Dynamic Air Filter (featured on certain models) regularly scrolls condenser air filter media to
maximize air flow and reduce maintenance
This manual is designed to guide you quickly through the process of installing and operating your Recirculating Chiller. We recommend that you read it thoroughly before you begin.
®
Environmental Control System with variable speed fan to reduce operational noise and
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General Information
• Always connect the power cord on this unit to a grounded (3-prong) power outlet. Make certain
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 heat removal. Please ensure that all individuals involved in the installation, operation or maintenance of this unit read this manual thoroughly prior to working with the unit.
This symbol alerts you to a wide range of potential dangers.
This symbol advises you of danger from electricity or electric shock.
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 Switch indicates that it places the unit in a standby mode. It DOES NOT fully disconnect the unit from the power supply.
This symbol indicates a protective conductor terminal.
Read all instructions pertaining to safety, set-up and operation.
Proper operation and maintenance is the user’s responsibility.
Safety Recommendations
To prevent injury to personnel and/or damage to property, always follow your workplaces safety procedures when operating this equipment. You should also comply with the following safety recommendations:
that the outlet is the same voltage and frequency as your unit.
• Never operate the unit with a damaged power cord.
• Always turn the unit OFF and disconnect Mains power before performing any maintenance or
service.
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Unpacking Your Chiller
Your Chiller is shipped in a special carton. Retain the carton and all packing materials until the unit is completely installed and working properly. Set up and run the unit immediately to confirm proper operation. Beyond one week, your unit may be warranty repaired, but not replaced. If the unit is damaged or does not operate properly, contact the transportation company, file a damage claim and contact the company where your unit was purchased immediately.
CAUTION: Keep unit upright when moving. Be sure to follow your company’s procedures and practices regarding the safe lifting and relocation of heavy objects.
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. 61010-2-010:15 - Safety Requirements for Electrical Equipment for Measurement, Control and Laboratory Use – Part 2-010: Particular requirements for laboratory equipment for the heating of materials
CAN/CSA C22.2 No. 61010-2-011- 2017 Safety Requirements for Electrical Equipment for Measurement, Control and Laboratory Use – Part 2-011: Particular Requirements for Refrigerating Equipment.
UL Std No. 61010-1 (2012) — Safety Requirements for Electrical Equipment for Measurement, Control and Laboratory Use - Part I: General Requirements.
UL 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
UL Std No. 61010-2-011 (2017) – Safety Requirements for Electrical Equipment for Measurement, Control and Laboratory Use - Part 2: Particular Requirements for Refrigerating Equipment.
CE (50Hz units)
Machinery Directive 2006/42/EC EC Electromagnetic Compatibility Directive 2014/30/EU IEC 61010-1 / EN 61010-1:2010 IEC 61010-2-011 IEC 61326:2012 / EN 61326:2013 RoHS Directive 2011/65/EU
Package Contents
The following items have been included with your Chiller:
• Operator’s Manual
• IEC Power Cord (select models)
• Two sets of Inlet/Outlet Adapters: 1/2 inch male NPT x 1/2 inch hose barb and 1/2 inch male NPT x 5/8 inch
hose barb (select models)
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Controls and Components
Front View — Air-Cooled Models
Rear View — Air-Cooled Models
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Quick Start
See Installation & Startup for additional information.
All models:
1
Connect all process lines
Remove reservoir cap
2
and fill reservoir with coolant
Connect
3
electrical power cord to Mains
Turn Power
4
Switch / Circuit Breaker ON
Press Standby
5
Button on front panel
Air-Cooled Models
Add coolant to reservoir as
6
process lines fill. Replace cap.
Press "SET = " To enter Set Point Screen
Use numeric keypad to enter desired set point. Press to save set point
and return to Home Screen
Enter
7
temperature set point
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Installation
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 5° and 40°C (41° and 104°F); relative humidity should not exceed 80% (non-condensing).
Location
• The Chiller should be installed on a strong, level surface.
• It should be located as close as possible to the process requiring cooling.
• It should not be installed closer than 4 feet (1.4 meters) to a heat-generating source, such as heating pipes,
boilers, etc.
• If possible, 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.
• Do not place it where access to the disconnecting device is impeded.
• 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 outlet wired with 14 gauge or larger diameter wire. 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.
Electrical Power
An IEC power cord is provided with the Chiller for select models. It should be attached to the receptacle on the rear of the enclosure. Make sure that the power outlet used for the Chiller is properly grounded and matches the voltage and frequency indicated on the identification label on the back of the Chiller.
The use of an extension cord is not recommended. However, if one is necessary, it must be properly grounded and capable of handling the total wattage of the unit. The extension cord must not cause more than a 10% drop in voltage to the Chiller.
WARNING: DO NOT plug the Chiller into the electrical outlet until the unit is ready for startup (see Startup on page 12).
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Optional Signal Inputs/Outputs
External Control / Ambient Tracking Temperature Probe
This option allows you to control the cooling fluid temperature using an external temperature measurement (ambient room/machine temperature or process temperature). A 9-pin connector is provided on the rear panel for connecting the external probe.
NOTE: In order to minimize process disturbance when using an external temperature probe, it is recommended that the external probe be connected to the unit before power is applied.
RS232 Serial Output
This option allows you to remotely control the Chiller and/or output temperature readings to an external recorder or other auxiliary device. The maximum communications distance for Chillers equipped with the RS232 option is 50 feet (15 meters). A 9-pin D-connector is provided on the rear of the instrument enclosure for this connection.
Remote I/O Port
This option allows you to use a dry contact closure to turn the Chiller on and off. Chiller status is also available from this port. A 15-pin D-connector is provided on the rear of the instrument enclosure for this optional connection. See schematic at the end of this manual.
USB Serial / TMC Output
This option allows you to remotely control the Chiller and/or output temperature readings to an external recorder or other auxiliary device. The port can be changed to behave as either a virtual com port, or as a USB TMC device by making the appropriate selection in the Menu. A type B connector is provided on the rear of the instrument enclosure for this optional connection.
Plumbing
Process Piping
The Chiller has two internally threaded (1/2 inch ID NPT) fittings on the rear of the instrument housing for the process water connections. Two sets of adapters (1/2 inch ID and 5/8 inch ID) are supplied with the unit for connecting these fittings to the process piping.
To maintain a safe workplace and avoid leaks, special care should be taken when choosing hoses and connectors for the Chiller. 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.
• Pressure Ratings — Hoses should be able to withstand the largest pressure that they will encounter.
For “P” Series (positive displacement pump) and “T” Series (turbine pump) Chillers, this is 100 psi (689 kPa).
• Flexible Tubing — Avoid tubing that will expand and take up fluid volume when operating at the desired
pressure.
• Hose Diameter — Process piping/hosing with a diameter smaller than ½ inch ID can be used if desired.
However, keep in mind that using smaller diameter hosing increases pressure in the circulating system.
• Couplings and Clamps — The use of screw-tightened hose clamps is necessary on all joints to insure good,
tight connections. Quick connectors are not recommended as they have the potential for restricting flow rate.
Drain
A connection is provided for the reservoir’s gravity drain. It should be piped to a drain or receptacle positioned below the bottom of the reservoir. If a receptacle is used, be sure it is of sufficient volume to hold all the water in the reservoir, process and process lines. This will also drain the fluid from the pump.
External Water Filter
An optional water filter is available that can be connected to the Chiller’s fluid inlet or fluid outlet. Consult supplier for additional information.
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Closed System or Cooling Coil Setup
Connect the Chiller’s inlet and outlet to the external apparatus with hoses or pipes. 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.
Open Bath System Setup
Position the external tank at least two feet (0.6 meter) above the Chiller’s inlet.
Install a shutoff valve on both the inlet and outlet of the Chiller. Place the valves in the closed position.
Connect the shutoff valves to the external tank using the tubing of equal diameter (1/2 inch minimum) and length. Use the same size fittings on both the inlet and outlet; this will ensure a balanced flow.
Cut the external end of the suction (inlet) tube into a “V” shape so that the tube will not seal itself against the wall of the external tank. Both the pressure and suction tubing should be securely fastened to the external tank to prevent movement during use. When using flexible tubing, the suction (inlet) tubing must have a wall thickness that will not collapse under vacuum, particularly when going around bends.
Fill the external bath (see Startup, Process Coolant on page 12 for suitable fluids).
Fill the Chiller reservoir to the bottom of the reservoir's fill port neck and install the cap. Tighten the cap until it is securely sealed.
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Startup
Process Coolant
Your Chiller must be operated with fluid in the reservoir. Always fill the reservoir before operation, to prevent damage to your unit. This section will provide you information on the selection and use of compatible fluids for your specific process.
Suitable Fluids
WARNING: Only use fluids that will satisfy safety, health, and equipment compatibility requirements. Caustic, corrosive, or flammable fluids must never be used.
WARNING: Do not use caustic, corrosive, or flammable fluids.
WARNING: Operation below 10°C (50°F) requires antifreeze in the circulation fluid.
CAUTION: Always select a fluid that is compatible with the Chiller’s wetted parts (brass, stainless steel, polyethylene, EPDM rubber, and nylon).
NOTE: For storage purposes, a very small amount (below 25mL) of laboratory grade propylene glycol is added
to the unit to avoid freezing damage to the pump. While this small amount will have no impact when mixed with other fluids, please refer to Routine Maintenance, Pump Drain for information on draining the pump.
WARNING: Do not use the following fluids:
• Automotive antifreeze with additives**
• Hard tap water**
• Deionized water with a specific resistance > 1 meg ohm (except units with the DI water compatible
plumbing
• Any flammable fluids
• Concentrations of acids or bases
• Solutions with halides: chlorides, fluorides, bromides, iodides or sulfur
• Bleach (Sodium Hypochlorite)
• Solutions with chromates or chromium salts
• Glycerin
• Syltherm fluids
** Additives or mineral deposits can adhere to internal components. If deposits are allowed to build up damage may result
to components such as the pump or heat exchanger. Higher temperatures and higher concentrations of additives can hasten deposit build up.
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Recommended Fluids
     
           
     
We recommend the following fluids be used with Chillers. Always verify fluid compatibility with the application in which the Chiller will be used and all wetted parts.
Fluid Temperature Range Recommended Maintenance
polyclear MIX 30 PLUS (distilled water plus clarifier and corrosion inhibitor)
polycool MIX -25 (50/50 mix distilled water and ethylene glycol)
Fluid Compatibility Table
Material of Construction
+10° to +90°C (+50° to +194°F)
-25° to +80°C (-13° to +176°F)
Verify fluid level monthly or more frequently per application needs.
Replace fluid every 3 months.
Fluid
polycool MIX -25 (50/50 premix of distilled water and ethylene glycol)
polyclear MIX 30 PLUS (distilled water plus clarifier and corrosion inhibitor)
polycool EG -25 concentrate (ethylene glycol)
polycool PG -20 concentrate (propylene glycol)
= compatible
The most common and acceptable coolant is a mixture of 50% distilled water and 50% ethylene glycol (laboratory grade), such as premix polycool MIX -25. This fluid mix will provide the best results for set points between -25° and +80°C (-13° and +176°F). Ethylene glycol helps lubricate pump seals and protects against freezing (the fluid temperature inside the Chiller may be below freezing even if the temperature at the outlet is over 0°C / +32°F).
Buna N
Tubing
®
Viton
Tubing
Braided
®
Teflon
Tubing
Nylon
Fittings
Brass
Fittings
Stainless
Steel
Fittings
We offer ethylene glycol (polycool EG -25) and propylene glycol (polycool PG -20) that can be mixed with an equal volume of distilled water to create a 50/50 water/glycol mix. Also available is a fluid clarifier to control inanimate organic particles (polyclean CLARIFIER).
Filling the Reservoir
Remove the filler cap from the reservoir and, using a funnel, add fluid until it reaches the bottom of the reservoir’s fill port. Once the reservoir is full, remove the funnel but do not replace the cap at this time.
Electrical Power
Plug the Chiller’s power cord into an appropriate electrical outlet.
Place the Circuit Breaker/Power Switch on the rear of the instrument enclosure in the “On” position. A standby screen will appear on the Chiller's display.
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Starting Process Fluid Flow
NOTE: When adding fluid to the unit for the first time, prime the pump by pressing the Standby Button
“On” and letting the Chiller run for 3 seconds and then pressing the Standby Button again to turn power “OFF”. Repeat this “On” and “Off” procedure three times.
Press the Standby Button on the front panel. The system startup sequence will begin and proceed as follows:
1. The pump will turn on and fluid will begin circulating through the system. The Home Screen will now be shown on the display. Fifteen to twenty seconds after power up, the compressor will begin operating.
2. Check for leaks.
3. With the pump running, the reservoir’s fluid level will drop as the process and/or process cooling lines fill with fluid. Add fluid as follows:
4. Closed Systems: Slowly add fluid to the reservoir until the liquid level remains stable
5. Open Bath Systems:
A. Open the inlet and outlet valves on the Chiller; the suction created by the pump should begin
drawing fluid through the inlet tubing into the Chiller reservoir.
B. Once flow is established (no air bubbles in inlet tubing), close the inlet and outlet valves and
turn the Chiller “Off”.
C. Remove the reservoir cap and check the level of the fluid in the reservoir. Add coolant until it is
level with the bottom of the reservoir's fill port neck.
CAUTION: Always close the inlet and outlet valves before turning power to the Chiller ”Off” or removing the reservoir cap to prevent the external reservoir from flooding the Chiller.
D. Replace the reservoir cap, open the inlet and outlet valves, and restart the Chiller.
E. Observe the liquid level in the external reservoir; adjust the valve on the Chiller outlet as required
to maintain a stable fluid level.
CAUTION: When running an open loop system for extended periods, the fluid level in the Chiller reservoir should be checked periodically to avoid low fluid conditions.
To check the reservoir fluid level, close the inlet and outlet valves, turn the Chiller ‘off’, and remove the reservoir cap. Slowly open the inlet and outlet valves and allow fluid to drain from the external reservoir into the Chiller reservoir. Close the valves when the fluid level within the Chiller reservoir reaches the top of the filler neck. Add fluid to the external reservoir as required. Replace the reservoir cap, open the inlet and outlet valves, and turn the Chiller back on.
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Normal Operation
This section provides information on all basic functions and normal operations involved in the daily use of your Chiller. Please familiarize yourself with all screens and functions before operating.
SPECIAL FEATURE: Air-cooled Chillers are equipped with the WhisperCool® Environmental Control System, which controls fan speed based on the heat load. You will notice the fan speed changing gradually during operation. This is especially beneficial in an environment where a low noise level is desirable.
Standby Screen
After energizing the Chiller, the Chiller will enter Standby Mode. In Standby, the fluid pump, refrigeration compressor, and condenser fan are all disabled. You may adjust Chiller settings in this mode by pressing from
this screen. Press the Chiller's Standby Button to begin operation. You will be taken to the Home Screen, and the Chiller's fluid pump, refrigeration and fluid temperature control functions will all be enabled.
Home Screen (Default Operation with Internal Probe Only)
The Chiller's Home Screen displays the readout of fluid temperature, temperature unit of measure, temperature set point, Chiller fluid pressure at the outlet, reservoir fill level, and airflow status. If there is an active Alarm or Warning, it will be displayed in the Status Bar.
Press the Set Temperature Button to adjust the fluid temperature set point.
Press the Settings Button to adjust other operating parameters such as Fahrenheit/Celsius selection.
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