PolyScience DuraChill 1.5 HP Operating Manual

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Operator’s Manual

DuraChill Air- and Water-Cooled 1.5 HP Chillers

110-392

11-03-11

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Table of Contents

Introduction.............................................................................................................................................................. 3

Standard and Optional Features............................................................................................................................ 3

Standard Features.............................................................................................................................................. 3

Optional Features............................................................................................................................................... 3

General Safety Information.................................................................................................................................... 4

Safety Recommendations...................................................................................................................................... 4

Regulatory Compliance and Testing...................................................................................................................... 6

Unpacking..............................................................................................................................................................6

Contents................................................................................................................................................................. 6

Controls and Components..................................................................................................................................... 7

Control Panel...................................................................................................................................................... 7

Front................................................................................................................................................................... 7

Rear -- 230V, 240V, and 208-230V Units .......................................................................................................... 8

Rear -- 380V and 460V Units............................................................................................................................. 8

Quick Start................................................................................................................................................................ 9

Installation and Startup......................................................................................................................................... 10

Site Requirements................................................................................................................................................ 10

Ambient Temperature and Relative Humidity .................................................................................................. 10

Location............................................................................................................................................................ 10

Clearance......................................................................................................................................................... 10

External Piping..................................................................................................................................................... 11

General Considerations.................................................................................................................................... 11

Process Fluid Connections............................................................................................................................... 12

Facility Water Connections............................................................................................................................... 12

Reservoir Drain................................................................................................................................................. 12

Reservoir Vent.................................................................................................................................................. 12

Process Coolant................................................................................................................................................... 13

Electrical Power ................................................................................................................................................... 14

Phase Requirements (if applicable) ................................................................................................................. 14

Optional Signal Inputs/Outputs............................................................................................................................ 14

Ambient / External Temperature Probe............................................................................................................ 14

RS-232/RS-485 Serial Output.......................................................................................................................... 14

Remote On / Off Port........................................................................................................................................ 14

4-20mA Set Point Control................................................................................................................................. 14

Startup.................................................................................................................................................................. 15

Facility Water Flow (water-cooled units only)................................................................................................... 15

Filling the Reservoir.......................................................................................................................................... 15

Starting Process Fluid Flow.............................................................................................................................. 15

Normal Operation .................................................................................................................................................. 16

Selecting the Temperature Unit........................................................................................................................... 16

Displaying and Adjusting the Set Point................................................................................................................ 16

Selecting the Internal / External Temperature Display ........................................................................................ 16

Displaying and Adjusting the Ambient Tracking Offset........................................................................................ 17

Displaying and Adjusting the Remote Control Temperature ............................................................................... 17

Selecting the Pressure / Flow Rate Display and Units ........................................................................................ 17

Setting Operational Parameters / Limits.............................................................................................................. 18

High Temperature Limit (HL)............................................................................................................................ 20

Low Temperature Limit (LL)............................................................................................................................. 21

High Ambient Temperature Limit (HA)............................................................................................................. 21

Maximum Fluid Pressure (FP).......................................................................................................................... 21

Minimum Flow Rate (FL).................................................................................................................................. 22

Auto-Refrigeration Temperature (AF)............................................................................................................... 22

Maximum External / Internal Temperature Differential (Sd)............................................................................. 22

Remote Probe (rP) ........................................................................................................................................... 23

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Internal Calibration Offset (c1) ......................................................................................................................... 23

External Calibration Offset (c2)........................................................................................................................ 24

Flow Rate Calibration (Fc)................................................................................................................................ 24

Current Control (CC) (Optional) ....................................................................................................................... 25

Baud Rate (PC)................................................................................................................................................ 25

Fuse Bits (Fb)................................................................................................................................................... 25

Display, Alarm and Error Messages.................................................................................................................... 26

Adjusting the High Pressure Bypass Setting..................................................................................................... 28

Enabling / Disabling the Local Lockout .............................................................................................................. 28

Over-Temperature Protection............................................................................................................................... 28

Routine Maintenance and Troubleshooting ....................................................................................................... 29

Routine Maintenance........................................................................................................................................... 29

Condenser, Air Vents and Reusable Filter....................................................................................................... 29

Fluid Filter......................................................................................................................................................... 29

Fluid Level........................................................................................................................................................ 29

Cleaning ........................................................................................................................................................... 29

Temperature Calibration................................................................................................................................... 29

Troubleshooting ................................................................................................................................................... 30

Diagnostic Mode .................................................................................................................................................. 31

Technical Information ........................................................................................................................................... 32

Controller Specifications...................................................................................................................................... 32

General Specifications......................................................................................................................................... 32

Pump Performance.............................................................................................................................................. 33

RS-232 / RS-485 Communications....................................................................................................................... 34

Equipment Disposal (WEEE Directive)................................................................................................................ 35

Service and Technical Support............................................................................................................................ 35

Replacement Parts ................................................................................................................................................ 35

Pumps.................................................................................................................................................................. 37

PolyScience Chiller Fluids.................................................................................................................................... 38

Warranty................................................................................................................................................................. 38

Appendix ................................................................................................................................................................ 39

Flow Schematic - All Models................................................................................................................................ 39

Electrical Diagram - 230V / 1PH / 50-60 Hz Models without heater option.........................................................40

Electrical Diagram - 230V / 1PH / 50-60Hz Models with heater option............................................................... 41

Electrical Diagram - 230V / 3PH / 50-60Hz Models without heater option..........................................................42

Electrical Diagram - 380-460V / 3PH / 50-60Hz Models without heater option................................................... 43

Electrical Diagram - 230V / 3PH / 50-60Hz Models with heater option............................................................... 44

Electrical Diagram - 380-460V / 3PH / 50-60Hz Models with heater option........................................................ 45

Options................................................................................................................................................................. 46

4-20 mA Set Point Control................................................................................................................................... 47

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Introduction

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.

Standard and Optional Features

The PolyScience DuraChill line of industrial Chillers offers exceptional performance, reliability, and operational simplicity. Available in both air- and water-cooled models, these robust self-contained Chillers are engine ered to provide accurate temperature control in a wide range of process cooling applications.

These powerful Chillers can be configured with a wide variety of standard and optional featur es, including: Standard Features

Process temperature: 41 to 95 F (5 to 35 C)

Ambient temperature: 60 to 95 F (16 to 35 C) Temperature stability: 0.9 F ( 0.5 C) Accurate microprocessor control with a digital LED readout Pump protection by means of a pump bypass valve Compressor protection through refrigerant pressure cutouts Process protection provided by over-temp/under-temp alarms Heavy-duty, locking casters provide easy maneuverability Stainless steel reservoir

Optional Features

Higher-output Centrifugal and Turbine pumps Heater (extends process temperature range to 41° to 194°F (5° to 90°C) Process shutoff valves RS232 interface RS485 interface Tank sight glass or level indicator Remote temperature control probe Audible and Visual Alarms Rail or foot mounting Tank low level indicator/alarm External water filter (side stream) DI compatible process piping Heaters Alternate heat transfer fluids

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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.

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 on the Power Switch / Circuit Breaker indicates that it places the unit into a fully powered state.

This symbol on the Power Switch / Circuit Breaker indicates that it disconnects power to the unit.

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.

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 question s regarding the operation of this Chiller or the information contained in this manual.

WARNING: Be sure to follow your company’s procedures and practices regarding the safe lifting and relocation of heavy objects.

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.

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WARNING: Exercise care when unloading, loading, rigging, or moving this equipment. Be sure to follow your organization’s procedures and practices regarding the safe lifting and relocation of heavy objects.

WARNING: All warning labels should be carefully observed. Never remove or obstruct a warning label.

WARNING: Make sure that ventilation is adequate when welding or brazing around this equipment.

Protect adjacent materials from flames or sparks. Keep an approved fire extinguisher close at hand.

CAUTION: Always operate this equipment within the stated design specifications.

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.

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

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

WARNING: Do not move the equipment without first disconnecting power.

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

disconnecting power.

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

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Regulatory Compliance and Testing

CSA UL (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 Measu reme nt, Co ntrol and Laboratory Use - Part 2-010: Particular Requirements for Laboratory Equipment for the Heating of Materials.

UL Std No. 61010-1 — Electrical Equipment for Laboratory Use, Part I: General Requirements. UL Std No. 61010A-2-010 — Electrical Equipment for Laboratory Use, Part 2: Particular Requirements for

Laboratory Equipment for the Heating of Materials.

CE (50Hz units)

EC Low Voltage Directive 2006/95/EC EC Electromagnetic Compatibility Directive 2004/108/EC IEC 61010-1-2001 IEC 61326:2005 / EN 61326 : 2006

Highly Accelerated Life Test (HALT) and Vibration Tests per ASTM D4169-8 (All units)

Unpacking

Your Chiller is shipped in a special container. Retain the container and all pa cking materials until the unit is completely assembled and working properly. Set up and run the unit immediately to confirm prope r 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.

Contents

 Recirculating Chiller  Operator’s Manual  Two sets of Inlet/Outlet Adapters, 0.5 inch male NPT  Power Cord (single phase units only)

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Controls and Components

Control Panel

Pressure / Flow

Rate Display

Pressure / Flow

Rate Units

Front

Bypass Valve Access Panel

Unit / Menu Select Button

Temperature Displa

Reservoir Cap and Fluid Filter Port

Temperature Units

Select / Set Knob

Power Button

Control Panel

Ambient / External Temperature Tracking Probe Connection (optional)

Air Filter

Air Filter Access

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Rear – 230V, 240V, and 208-230V Units

Power Switch / Circuit Breaker

Communications Port (optional)

RS-232 Port (optional)

Reservoir Vent

(Vent Assembly required

on 5XXX models)

IEC Electrical

Connection

Facility Water Outlet

(water-cooled models)

Reservoir Drain

Remote Temperature Probe Port (optional)

Fluid Inlet (from process)

Fluid Outlet (to process)

Over-Temperature Protection Adjust (5XXX models only)

Over-Temperature Protection Reset (5XXX models only)

Facility Water Inlet (water-cool models)

Rear – 380V and 460V Units

Vent Assembly

(supplied with

5XXX models)

Electrical Connections

Junction Box f

Power Switch

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Quick Start

See Installation & Startup for additional information.

All units: Connect process lines

Water-cooled units:

A. Connect process lines B. Connect facility water lines C. Turn facility water ON

Fill reservoir with coolant

Connect electrical power to Mains

Turn Power Switch / Circuit Breaker ON

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Turn Controller ON

Add coolant to reservoir as process lines fill

Enter temperature set point

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 1 6° and 35°C (60° and 95°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 to possible to the process requiring cooling. It should not be installed closer than 4 feet (1.4 meters) to a heat-generating source, such as heating pipes, boilers, etc. If possible, 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 conn ections 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

Reservoir Vent

(shown wi t h Vent

Assembly for

5XXX models))

Reservoir Drain

Process Fluid Inlet

Process Fluid Outlet

Facility Water Inlet

Facility Water Outlet

WARNING: All facility water connections must be made by a licensed plumber.

General Considerations

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.

• Take care when selecting hoses and connections for the Chiller. 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 pres sure that they will encounter (100 p si

/ 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

The Chiller has two internally threaded (0.5 inch ID NPT) fittings on the rear of the instrument housing for the process water connections. Two sets of adapters (0.5 inch ID an d 0.625 inch ID) are supplied with the unit for connecting these fittings to the process piping.

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.

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.

Facility Water Connections

WARNING: The incoming cooling water pressure should be 20 psi / 1.4 bar minimum and 150 psi / 10.3 bar

maximum.

Water-cooled Chillers have two internally threaded (0.75 inch ID NPT) on the rear of the instrument housing for the facility water connections. The cooling water supply should be connected to the facility water 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. The incoming water pressure should be between 20 and 150 psi / 1.4 and 10.3 bar.

Reservoir Drain

A 0.5 inch NPT 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 coolant in the reservoir, process, and process lines.

Reservoir Vent

A reservoir vent assembly is provided with Chillers equipped with the heater option. This vent relieves pressure within the reservoir as coolant heats and expands. A 0.5 inch NPT connection is provided on the rear of the Chiller for connecting the vent assembly.

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Process Coolant

Suitable Fluids

WARNING: Only use fluids that will satisfy safety, health, and equipment compatibility requirements. Caustic,

corrosive, or flammable fluids must never be used.

The Chiller is designed to accommodate a variety of coolant fluids (water, glycol mixtures, etc). For most applications above 15°C (59°F), distilled water is satisfactory. For operation below 15°C (59°F), the Chille r must be protected with an antifreeze solution. Ethylene glycol (laboratory grade) and water in a 50/50 mixture is satisfactory from +15° to -15°C (59° to 5°F). Select a fluid that is compatible with the Chiller’s wetted parts (brass, bronze, stainless steel, EPDM rubber, nylon, PVC).

WARNING: Do not use caustic, corrosive, or flammable fluids.

WARNING: Operation below 15°C (59°F) requires antifreeze in the circulation fluid. DO NOT use automotive

antifreeze as the additives may be harmful to the Chiller’s wetted parts.

CAUTION: 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

** 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 can hasten deposit build up.

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Electrical Power

Use the voltage and amperage requirements specified on the data plate on the back of the unit. Connect the power cord (if) supplied with the Chiller to an appropriate electrical outlet. Avoid voltage drops by

using properly grounded power outlets. If possible, locate the Chiller close to the power distribution panel or 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. 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%.

You can minimize low line voltage problems by eliminating the use of extension cords or long supply conduits.

WARNING: Make sure electrical connections comply with all applicable electrical codes.

Ground the Chiller in accordance with NEC Article 250. Operation voltage must be within 10% of th e data plate rating.

WARNING: DO NOT apply power to the Chiller until the unit is ready for Startup.

Optional Signal Inputs/Outputs

Ambient / External 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 conne ctor is provided on either the underside of the front control panel or on the rear panel for connecting the ambient/external tracking probe.

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.

RS-232 / RS-485 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). The maximum distance for units equipped with the RS485 option is 4000 feet (1200 meters). A 9-pin D-connector is provided on the rear of the instrument enclosure for this connection.

Remote On / Off Port

This option allows you to connect a remote on/off switch or other remote control device to the Chiller. A 15-pin Dconnector is provided on the rear of the instrument enclosure for this connection. See Appendix, Options for wiring information.

4-20mA Set Point Control

This option allows you to change set point per customer supplied current value. A 15-pin D-connector is provided on the rear of the instrument enclosure for this conne ction. See Appendix, Options for wiring information.

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Startup

Facility Water Flow (water-cooled units only)

1. Open the val v es to the facility water supply and return.

2. Check for leaks.

Filling the Reservoir

1. Rem ove 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 pum p 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. Repl ace the reservoir cap.

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Normal Operation

NOTE: The Chiller incorporates a special “lockout” feature that can be enabled to prevent unauthorized or

accidental set point and other operational changes. This feature is described in detail under “Enablin g and Disabling the Local Lockout.” It should not be enabled until all operational parameters have been set.

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.

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 the desired values.

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.

NOTE: Temperature set point cannot be changed when the local lockout is enabled or when the optional ambient temperature tracking feature is installed and enabled. See “Enabling and Disabli ng the Local

Lockout, Displaying and Adjusting the Ambient Tracking Offset” and “ Setting Operational Parameters, Remote Probe”.

Selecting the Internal / External Temperature Display

NOTE: This section applies only when 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 outl et fluid temperature or the external ambient/process temperature.

When the ambient tracking probe is selected (AtC, see “Setting Operational Parameters, Remote Probe”), 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, see “Setting Operational Parameters, Remote Probe” ), 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.

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).

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Displaying and Adjusting the Ambient Tracking Offset

NOTE: Ambient tracking is an optional function that may or may 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.

When the optional ambient tracking probe is installed and enabled (AtC, see “Setting Operational Param eters, Remote Probe”), 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 until the desired offset 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

NOTE: Remote temperature control is an optional function that may or may not be available on your Chiller.

It permits you to control cooling based on the temperature of an external process.

When the optional remote control external probe is installed and enabled (rP, see Setting Operational Parameters, Remote Probe), 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 be set up to display either fluid pressure (in PSI or kPa) or, if fitted with flow sensor, flow rate in GPM or LPM. Pressing the Units/Menu Select Button briefly toggles through the available selections.

NOTE: Metric pressure reading output is displayed in kPA and must be multiplied by 100 for kPa.

NOTE: If there is no flow sensor fitted, the display will show “- -“ when GPM or LPM is selected.

NOTE: The flow rate readout is intended as a reference only. If accurate flow readings are required, an

external flow meter is recommended.

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Setting Operational Parameters / Limits

The Chiller’s various operational parameters, such as temperature, flow rate, and pressure alarm values, are all 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 app ears 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

NOTE: Some parameters listed may not be included in your version of software.

NOTE: The Ranges and Default Settings shown are for standard models. Ranges and Default Settings for your unit may differ depending on the options selected.

Menu Item Description Choices / Ranges Default Setting

Units without heater

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 current set point.

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 (68ºF). Performance will decrease as the ambient temperature rises. Continuous operation at ambient temperatures above 40ºC (104ºF) is not recommended.

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

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 maximum outlet 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.

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.

20 to 100 PSI 13 to 680 kPa

(display value x 100)

0 and 1.5 to 3 GPM

0 and 6 to 11 LPM

+20° to 40°C 35°C

80 PSI

5.5 x 100 = 550 kPa

1.5 GPM

6.0 LPM

C1 / C2

Maximum External / Internal Temperature Differential

(optional) — Establishes 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.

Calibration Offset — Allows adjustment of the displayed

temperature to match that of an independent traceable standard; 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.

4° to 20°C 5°C

Dependent on option and

software installed.

±2.9°C 0.0°C

Note value here for

reference/replacement of

PCB or flow sensor

nAP

Varies

110-392 19

Menu Item

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.

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.

Input

Remote ON / OFF

dry contact

Logic

State

Closed Off On Off On

Open On Off

h00 h01 h02 h04 h05 h06

Yes or No No

24 (2400), 48 (4800),

96 (9600) or 192 (19200)

N/A

On Off

9600

N/A

Fuse Bits

24 VDC Remote

Control Voltage

24 VDC Off Off On Off On

N/A

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

You can adjust the following settings for your particular application or simply accept the default values.

High Temperature Limit (HL)

This menu item serves two functions. First, it establishes the maximum allowable set point temperature and thus helps prevent an operator from inadvertently selecting a temperature set point above a pre-established value. Secondly, it serves as a high temperature alarm, automatically activating both audio and visual alarm indicators if the measured fluid temperature reaches the HL setting. This also causes the compressor, heater, fan, and pump to turn off.

To change the high limit value, rotate the Select/Set Knob until the desired value is displayed.

110-392 20

Low Temperature Limit (LL)

This menu item also serves a dual function. First, it establishes the minimum allowable set point temperature and thus helps prevent an operator from inadvertently selecting a temperature set point below a pre-established value. Secondly, it serves as a low temperature alarm, automatically activating both audio and visual alarm indicators if the measured fluid temperature drops to the LL setting. This also causes the compressor, heater, fan, and pump to turn off.

To change the low limit value, rotate the Select/Set Knob until the desired value is displayed.

High Ambient Temperature Limit (HA)

NOTE: This value is always set in °C.

This menu item protects the Chiller from overheating due to a high ambient temperature. Should the ambient temperature rise above the limit value, the audio and visual alarms will activate and the compressor, heater, fan, and pump will turn off.

To change the high ambient temperature value, rotate the Select/Set Knob until the desired value is displ ayed on the Temperature Readout.

Maximum Fluid Pressure (FP)

This is the maximum allowable fluid pressure and can be set in either PSI or kPa (the LED adjacent to the display indicates the active unit of measure). 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.

To change the fluid pressure limit value, rotate the Select/Set Knob until the desired value is displayed on the Temperature Readout.

NOTE: When FP first appears, the PSI LED will be lit. To view the FP value in kPa, press the Units/Menu Button again. The FP will remain on the display, and the kPa LED will light up.

PSI

NOTE: Chillers with positive displacement and turbine pumps also incorporate a built-in safety that automatically maintains fluid pressure below a valve-regulated pressure value. It maintains this maximum outlet pressure by diverting the flow of process fluid to the reservoir (i.e., begin internally recirculating the fluid). A maximum pressure value is set at the factory, but is user-adjustable. See “Adjusting the High Pressure Bypass Setting” for information on changing the maximum outlet pressure value.

110-392 21

kPa x 100

5.5

Minimum Flow Rate (FL)

NOTE: If flow rates are below 1.5 GPM (6 LPM), this feature is not recommended as nuisance alarms may

result.

This is the minimum allowable flow rate and can be set in either GPM or LPM (the LED adjacent to the display indicates the active unit of measure). 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.

To change the minimum flow rate value, rotate the Select/Set Knob until the desired flow rate value is displayed on the Temperature Readout.

With FL set to “0”, the flow alarm is disabled, and the Chiller will continue to operate with the output flow blocked.

NOTE: When FL first appears, the GPM LED will be lit, indicating the FL value is GPM. To view the FL value in LPM, press the Units/Menu Button again. The FL will remain on the display and the LPM LED will light up.

GPM

●

LPM

●

1.5

Auto-Refrigeration Temperature (AF)

NOTE: This value is always displayed/set in °C.

This menu item allows you to select the temperature at which refrigeration is activated. When the set point exceeds the auto-refrigeration temperature by more than 1.0°C, the cooling and the fan are turned off.

To change the auto-refrigeration temperature, rotate the Select/Set Knob until the desired value is displayed.

Maximum External / Internal Temperature Differential (Sd) (optional)

NOTE: This menu item (Sd) is only applicable when the remote temperature control probe is installed and

enabled.

This value helps establish the cooling/heating rate when the remote temperature control probe is being used.

Maximum external/internal differential temperature values from 4° to 20°C may be entered. The higher the setting, the more rapidly the Chiller will achieve the external temperature set point. Low differential temperature settings minimize the amount of temperature overshoot/undershoot that occurs when the measured external temperature reaches the external set point temperature.

110-392 22

5.0

Remote Probe (rP)

NOTE: If an external temperature probe is not installed, n-A will be displayed when this menu item is

selected.

This menu item allows you to enable/disable the Chiller’s optional ambient temperature probe (AtC) or remote temperature control probe (rPC).

If you wish to operate the Chiller using the ambient tracking probe, rotate the Select/Set Knob until AtC is displayed. When this setting is selected, the effective set point for the cooling fluid temperature will be the temperature sensed by the ambient tracking probe (this may be room or machine temperature) plus or minus an offset specified by the user (see “Displaying and Adjusting the Ambient Tracking Offset” ).

If you wish to operate the Chiller using the remote temperature probe, rotate the Select/Set Knob until rPC is displayed. When this setting is selected, the fluid temperature is controlled according to the temperature sensed by the external probe. The rate of cooling is controlled through the maximum differential temperature setting (Sd) (see “Maximum External / Internal Temperature Differential”).

If you do not wish to operate the Chiller using either of these external probes, rotate the Select/Set Knob until NO is displayed.

Internal Calibration Offset (C1)

IMPORTANT: To prevent the operator from accidentally changing the calibration offset, a special keystroke

sequence is required to access this function.

AtC

rPC

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.

NOTE: Calibration offset values are always set and displayed in °C.

1. Press an d hold the Units/Menu Button until HL appears on the display.

2. Press an d release the Units/Menu Button until rP appears on the display.

3. Press an d hold

4. While holding the Units/Menu Button, press and release the Select/Set Knob.

5. When CL1 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 temperature reading (enabling you to simultaneously adjust the offset and see the effect on the temperature).

6. Rotate the Select/Set Knob until the desired calibration offset is displayed. Press the Select/Set Knob or simply allow the display to time out to accept the displayed value.

110-392 23

the Units/Menu Button.

External Calibration Offset (C2)

IMPORTANT: To prevent the operator from accidentally changing the calibration offset, a special keystroke

sequence is required to access this function.

0.0

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.

NOTE: Calibration offset values are always set and displayed in °C.

1. Press and hold the Units/Menu Button until HL appears on the display.

2. Press and release the Units/Menu Button until

3. Press and hold

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 temperature reading (enabling you to simultaneously adjust the offset and see the effect on the temperature).

6. Rotate the Select/Set Knob until the desired calibration offset is displayed. Press the Select/Set Knob or simply allow the display to time out to accept the displayed value.

the Units/Menu Button.

1 appears on the display.

Flow Rate Calibration (Fc)

NOTE: Your Chiller’s flow rate is calibrated at the factory at the nominal flow value for the installed pump.

Further adjustment is not necessary.

0.0

This menu item allows you to adjust the flow rate display to match that of a known standard.

1. Press and hold

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

4. While holding the Units/Menu Button, press 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.

the Units/Menu Button until HL appears on the display.

the Units/Menu Button.

0.0

110-392 24

Current Control (CC) (Optional) This optional menu item allows you to adjust the temperature set point using a 4-20 mA analog signal. To change

the displayed setting, rotate the Select/Set Knob until the desired selection is displayed (yES = enabled; NO = disabled).

Baud Rate (PC)

This menu item allows you to establish the baud rate for serial communication. Allowable settings are 0 (no serial communication), 24 (2400 baud), 48 (4800 baud), 96 (9600 baud), 192 (19200 baud).

To change the displayed setting, rotate the Select/Set Knob until the desired baud rate is displayed. Press the Select/Set Knob or 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 Select/Set Knob and Power Button, 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.

h00

110-392 25

Display, Alarm and Error Messages

When certain conditions are detected, a message code flashes on t he display and the local audio alarm sounds. Depending on the nature of the condition, power to various systems components, such as the compressor, heater, fan, and pump, 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.

Message Code Description Action Required

Low fluid level warning —

EFL

EHA

EHL

units with fluid level float switch.

Fluid flow too low warning — units with flow

switch (PO - no pump – no reservoir option).

High ambient temperature warning

High limit temperature alarm

Warning / Alarm — Fluid level or flow switch is open. Alarm will

sound once every 8 seconds for 5 occurrences. If problem has not been corrected after 40 seconds, Fault 05 occurs.

Add fluid to the reservoir.

Warning / Alarm - The ambient temperature (as measured on the Control PCB) is higher than the set ambient limit. The display 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 high ambient temperature limit. Warning / Alarm — The temperature set point is higher than the high

temperature limit value. The display alternates between EHL and the fluid temperature; the unit continues normal operation. If the fluid temperature stays above the HL value for more than 25 seconds, Fault 03 occurs.

Lower temperature set point or increase high limit value. 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. If the fluid temperature stays below the LL value for 25 seconds, Fault 02 occurs.

Increase temperature set point or decrease low limit value. Warning / Alarm — LO is displayed alternately with H2O and fluid

temperature if the fluid pressure exceeds the high pressure limit or if the fluid flow is less than the low flow limit. If either error lasts for more than 10 seconds, Fault 08 or Fault 07 (respectively) occurs.

Normal — Indicates that Local Lockout feature (see Enabling / Disabling the Local Lockout) is enabled. Appears momentarily when

Select/Set Knob is pressed to view/change set point value. Normal — Indicates the Local Lockout feature (see Enabling /

Disabling the Local Lockout) has been disabled. Appears momentarily when Local Lockout status is changed from enabled (LLO) to disabled.

Normal — Chiller is in Standby mode until remotely activated (optional).

ELL

LO-

H2O

LLO

CAn

Low temperature limit alarm

No fluid flow and no fluid pressure

Local Lockout

Cancel Local Lockout

External remote control active

110-392 26

If a fault should occur, the left display will show Ft, and the right display will show one of the fault codes shown below.

Fault Code Description Action Required

Alarm — Process fluid temperature is below the low 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 using the front panel Power Button, and decrease the LL value.

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 using the front panel Power Button, and increase the HL value.

Alarm — Process fluid temperature is above Chiller’s factory set high temperature safety cutoff. Heater, compressor, and fan turned off; pump remains on.

Lower process temperature. 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 off.

Add fluid to reservoir. Alarm — F low rate has dropped below minimum flow rate setting for

more than 10 seconds. Compressor, heater, fan, and pump are turned off. Note: Disabled during first 2 minutes of operation.

Correct cause of low flow rate or decrease minimum flow rate setting. Alarm — Fluid outlet pressure has exceeded high-pressure limit

value for over 10 seconds. Compressor, heater, fan, and pump are turned off.

Decrease outlet pressure by removing blockage or increase highpressure limit value.

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, contact service representative.

Fault — Heater triac has failed for more than 10 seconds. Compressor, heater, fan, and pump are turned off.

Contact service representative. Fault — Main temperature control probe has failed for more than 4

seconds. Compressor, heater, fan, and pump are turned off. Contact service representative. Fault — External temperature control probe has failed for more than

4 seconds. Compressor, heater, fan, and pump are turned off. Replace ambient tracking probe or operate instrument using internal

temperature probe. Contact service representative if fault persists. 4-20 mA Option — Input for temperature set point too high or too

low. Correct input or switch to standard control.

Low limit temperature alarm

High limit temperature alarm

Over-temperature alarm

Low liquid level alarm

(select models only)

Low flow alarm

High pressure alarm

Internal software fault

Electronic power component fault (Triac)

Internal probe fault

External temperature probe fault

(select models only)

Input – Out of Range

110-392 27

Adjusting the High Pressure Bypass Setting

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 housi ng.

WARNING: There are exposed fan blades inside the Chiller housing. Exercise extreme c are when accessing or adjusting any interior components.

WARNING: Hazardous voltages are present.

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 Operational Parameters, Minimum Flow Rate). This will

prevent the unit from activating the flow alarm while you are adjusting the maximum pressure setting.

2. Completely 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.

Locknut

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 (approximately 5 seconds). 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 (approximately 5 seconds).

IMPORTANT: The Local Lockout feature does not prevent set point changes entered via the RS232 interface or 4-20 mA inputs.

Over-Temperature Protection

Chillers with the heater option are equipped with an adjustable OTP which disconnects power to the heater should the liquid level in the reservoir drop too low. The OTP is factory set to disconnect power at a temperature of 60°C for 6XXX models and 95°C for 5XXX models. Consult factory for instructions on setting the OTP to trip at a lower temperature.

110-392 28

Routine Maintenance and Troubleshooting

Routine Maintenance

The Chiller is designed to require a minimum of periodic maintenance.

Condenser, Air Vents and Reusable Filter

To keep the system operating at optimum cooling capacity, 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 easily 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.

Fluid Filter

A removable, highly efficient fluid filter is integrated into the fluid reservoir. To remove it for cleaning, simply remove the reservoir cap and lift the filter out of the reservoir. Rinse off accumulated particulate matter and reinstall.

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.

NOTE: On units equipped with the heater 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.

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.

Temperature Calibration

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. See “Setting Operational Parameters, Internal Calibration Offset and External Calibration Offset”.

110-392 29

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 Po wer Button on the front panel while returning the Power Switch/Circuit Breaker to the

ON position.

WARNING: Refer servicing to qualified service personnel.

WARNING: When electrical power is ON, dangerous voltages exist within chassis components. Use extreme

care when measuring voltages on live circuits.

Problem Possible Causes Corrective Action

Unit does not run

No power to unit

(digital displays blank)

Unit does not run

Unit in Standby mode Press Power Button on front panel. (three decimal points appear on Temperature Display, two decimal points on Pressure/Flow Rate Display)

No fluid circulation Insufficient fluid in reservoir

Blockage in circulating system

Pump is not operating Insufficient circulation Fluid viscosity too high

External tubing diameter too

small

Restrictions in fluid lines

Low line voltage 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

Unit does not heat

OTP has tripped due to

Insufficient fluid in reservoir Fault code 10 on display

Extreme electrical line

interference

Triac failure

Check that the electrical cord or wiring is secure and connected to an operating electrical source.

Check that Power Switch / Circuit Breaker on rear of unit is ON.

Add fluid to reservoir. Remove blockage. Replace pump. Replace with lower viscosity fluid. Replace with larger diameter tubing.

Check and correct as required. Check and correct as required. 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.

Add fluid to reservoir and reset OTP.

Plug unit into another power source. If problem persists, triac has failed.

Replace triac or triac driver as required.

110-392 30

Problem Possible Causes Corrective Action Fault code 11 on display Internal probe failure Contact service representative. Fault code 12 on display Loose external probe

connection

Faulty external temperature

probe

Check and correct as required.

Replace as required.

NOTE: Chiller may be operated using internal probe until problem is corrected.

Diagnostic Mode

NOTE: The Chiller must be set up to display temperature in °C in order to access the 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 Tempe rature Readout.

NOTE: Diagnostic items are display values only; they cannot be changed..

Menu Item Description

At Ambient temperature at front panel

EC External control

Li Percent of Line voltage Ct Chil ler type (model) Fb Fuse bits (remote control voltage, contact closures, etc.)

EP 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

110-392 31

Technical Information

Controller Specifications

Temperature Set Point Resolution ±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

General Specifications

Model Air-Cooled

58XX & 68SS Series

Compressor Nominal HP 1.5 Temperature Range

(without heater option) Temperature Range

(with heater option) Temperature Stability °F

Cooling Capacity 1 Tons

Nominal Evaporator Flow 2 US GPM 3.72 4.3 Refrigerant R134A Pressure 3 PSIG 60 Pump 3 HP 1/3 Fan(s) HP 1/6 N/A Condenser Discharge Air Flow CFM 1070 N/A Water Condenser Flow – Tower Water US GPM N/A 5.4 Water Condenser Connections Inches N/A 0.75 Process Connections (inlet / outlet) Inches 0.5 Reservoir Tank Capacity US Gallons (liters) 3.5 (13.25) Dimensions (L x W x H) Inches

Shipping Weight Pounds

Nominal Rated Amps 3

°F °C

°C

1.48 Watts BTU/hour

kg Without heater option 230V/1/60

240V/1/50 208-230V/3/60 14.8A 13.7A 380V/3/50-60 7.5A 6.95A 460V/3/50-60 7.5A 6.95A

5200

17,732

20.8A

21.5A

41° to 95°F

5° to 35°C

41° to 194°F

5° to 90°C

30.5 x 19 x 26”

78 x 48 x 66 cm

Water-Cooled

59XX & 69XX Series

±0.9°F ±0.5°C

1.8

6328

21,600

340 154

19.7A

20.4A

110-392 32

Nominal Rated Amps 3

With heater option 240V/1/60

29A 27.9A

(3000W heater) 208-230V/3/50-60

37.1A 36A

(7500W heater) 208-230V/3/50-60

42.6A 41.5A

(9000W heater) 380V/3/50-60

22.7A 22.15A

(9000W heater) 460V/3/50-60

22.7A 22.15A

(9000W heater)

1. Capacity of air-cooled units based on 68°C (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

3. Based on positive displacement pump for 1PH units and 3/4 HP turbine pump for 3 phase units. Refer to pump performance chart for other pumps. See data plate on rear panel for amperage of your Chiller with factory installed configuration and options.

/hr/ton).

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

Pump Performance

120

100

PSI

02468101214

P9 P4 P6

1.5 HP Pum ps

GPM

P4 3. 5 GPM P osit i ve Displacement P6 4 GPM Positive Displacement P9 2. 33 GP M Posit i ve Displacement M5 Mag Drive Centrifugal T2 1/3 HP Tur bine T5-T6-T7-T8 3/4 HP Turbine T9-TE 1 HP Tur bin e S1 Speck Pump 7.5 GPM

1 HP3/4 HP

Specifications subject to change without notice.

110-392 33

RS-232 / RS-485 Communications

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:

Pin #2 — data read (data from computer) Pin #3 — data transmit (data to computer) Pin #5 — signal ground

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).

— The controller uses the following RS-232 / RS-485 protocol:

Communications Commands

— Commands must be entered in the exact format shown. Do not send a [LF] (line feed) after the [CR] (carriage return). Be sure to follow character case exactly. A question mark (?) 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

Set command echo SEi[CR]

Set on / off SOi[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] 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]

Command

Format

Values Return Message

Echo: i = 1 No Echo: i = 0

On: i = 1 Off: i = 0

1 = Run 0 = Standby

![CR]

1[CR] or 0[CR]

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Equipment Disposal (WEEE Directive)

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.

It is your responsibility to correctly dispose of this equipment at lifecycle-end by handing it over to an authorized facility for separate collection and recycling. It is also your responsibility to decontaminate the equipment in case of biological, chemical and/or radiological contamination, so as to protect the persons involved in the disposal and recycling of the equipment from health hazards. By doing so, you will help to conserve natural and environmental resources and you will ensure that your equipment is recycled in a manner that protects human health.

Requirements for waste collection, reuse, recycling, and recovery programs vary by regulatory authority at your location. Contact your local responsible body (e.g., your laboratory manager) or authorized representative for information regarding applicable disposal regulations.

Service and Technical Support

If you have followed the troubleshooting steps and your Recirculating Chiller fails to operate p roperly, contact the supplier from whom the unit was purchased. Have the following information available for the customer service person:

— Model, Serial Number, and Voltage (from back panel) — Date of purchase and your purchase order number — Suppliers' order number or invoice number — A summary of your problem

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Replacement Parts

Description Part Number

Controller PCB

NOTE: When replacing the Controller PCB, it is important to note the software version. You can obtain the software version by pressing and holding the Power Button on the controller while the unit is in “Standby”. For our standard software the left display will read “T3” and the right display will read “003” or software version T3-003. If you are unable to obtain the software version, your model number and serial number will be required.

RTD Temperature Sensor 200-430 Remote / Ambient Tracking Probe, 10’ cable, DB9 Female Plug 060101 Remote / Ambient Tracking Probe, 25’ cable, DB9 Female Plug 060105 Remote / Ambient Tracking Probe, 50’ cable, DB9 Female Plug 060110 Fluid Pressure Sensor, Standard 750-381 Fluid Pressure Sensor, SS, DI units 750-384 Switch, Circuit Breaker, 20 Amp, 1PH 215-388 Flow Sensor, Hall Effect, Honeywell 330-087

500-251

Float Switch, Water Level, Single Float @ 7.0” 235-061 Float Switch, Water Level, Dual Float, @ 6.8/8.0” 235-064 Compressor,1.5HP,COP#CS18K6E-PFV-230, 230/1/60 750-376 Compressor,02.00HP,COP#CS18K6E-PFJ-230, 200-240/1/50 750-413 Compressor,02.00HP,COP#CS18K6E-TF5-230, 230/3/50-60 750-333 Compressor,02.00HP,COP#CS18K6E- TFD-230, 380-460/3/50-60 750-773 Motor, Fan, 230V, Emerson # 050-0265-00 215-519 Motor, Fan, 380-460V, Emerson # 950-0265-01 215-629 Heater Cartridge, 240V, 1000W 215-459 Heater Cartridge, 240V, 2500W 215-564 Heater Cartridge, 240V, 3000W 215-567 Heater Cartridge, 460V, 1000W 215-654 Heater Cartridge, 480V, 3000W 215-644 Solid State Relay, 50 Amp, Crydom HA6050-10 (for Heaters) 200-343 Solid State Relay, 25 Amp, 48-600V, 3-32CV (Compressor) 200-225 Contactor, ABB A9-30-10-36 215-468 Contactor, ABB A26-30-10-36 215-674 Capacitor, Start, Compressor, 145-174MFD, 250v, COP#914-000-607 750-336 Capacitor, Run, Compressor, 35MFD,370V, COP#914-0037-11 (60HZ) 750-337 Capacitor, Run, Compressor, 45MFD,370V, COP#914-0037-18 (50HZ) 750-414 Relay, Compressor, COP#040-0166-15, COP#040-0166-15 750-338 PCB, 4-20mA Set Point Control 500-342

110-392 36

Description

Part Number

High Pressure Control, Penn#P100CC-9C, 275/175 215-473 Compressor Pressure Regulator Valve, SP#CRO-T-6-30/110-5/8ODF 750-766 Valve, Refrigeration, Liquid and Hot Gas Bypass, PK#DS1100,240VAC 750-179 Filter Dryer, SP#C-053-S, 3/8ODF 750-075 Air Filter, Condenser 750-387 Operator’s Manual 110-392

Pumps

Description Part Number

P4 – Positive Displacement, Rotary Vane, Bronze, 3.5 GPM, 240V/1PH/50-60HZ

P6 – Positive Displacement, Rotary Vane, Stainless Steel 4 GPM, 240V/1PH/50-60HZ

P9 – Positive Displacement, Rotary Vane, Bronze, 2.33 GPM,240V/1PH/50-60HZ M5 – Mag-Drive Centrifugal Pump, 240V/1PH/50-60HZ 525-552

S1 – Speck Centrifugal, Stainless Steel, 7.5 GPM, 240V/1PH/50-60HZ 215-306 T2 – 1/3HP Turbine, Bronze 3.5 GPM, 240V/1PH/50-60HZ 215-305 T5 – 3/4HP Turbine, Bronze, 240V/1PH/50-60HZ 215-499 T6 – 3/4HP Turbine, Stainless Steel, 240V/1PH/50-60HZ 215-474 T7 – 3/4HP Turbine, Stainless Steel, 208-230V/3PH/50-60HZ 215-475 T8 – 3/4HP Turbine, Bronze, 208-230V/3PH/50-60HZ 215-487 T9 – 1HP Turbine, Stainless Steel, 208-230V/3PH/50-60HZ 215-568 TC – 1/3HP Turbine, Bronze, 208-230V/3PH/50-60HZ 215-364 TD – 1HP Turbine, Bronze, 208-230V/3PH/50-60HZ 215-651 TE – 1HP Turbine, Bronze, 240V/1PH/50-60HZ 215-655

Pump – 215-106 Motor – 215-217

Pump – 215-280 Motor – 215-217

Pump – 215-218 Motor – 215-217

Pump assemblies include motor unless listed separately.

110-392 37

PolyScience Chiller Fluids

Circulating Bath Fluids Quantity Part Number

polyclean Algaecide 8 oz / 236 ml 004-300040 polyclean Algaecide Twelve 8 oz / 236 ml bottles 004-300041 polycool EG -25 (ethylene glycol) 1 gal / 4.5 liter 060340 polycool PG -20 (propylene glycol) 1 gal / 4.5 liter 060320 polycool HC -50 (water-based heat transfer fluid) 1 gal / 4.5 liter 060330 polycool MIX -25

(50/50 blend polycool EG -25 / H algaecide)

O plus polyclean

Five

0.5 gal / 2.27 liter bottles

004-300060

Warranty

NOTE: The Warranty on DuraChill and other custom-designed products appli es on ly to the original end user

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. Pl ease contact your supplier for additional warranty details and service contract information.

The manufacturer agrees to correct for the original user of this product, either by repair, or at the manufacturer's election, by replacement, any defect that develops after delivery of this product 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.

110-392 38

Appendix

Flow Schematic - All Models

110-392 39

Electrical Diagram – 230V / 1PH / 50-60Hz Models without heater option

110-392 40

Electrical Diagram – 230V / 1PH / 50-60Hz Models with heater option

110-392 41

Electrical Diagram – 230V / 3PH / 50-60Hz Models without heater option

110-392 42

Electrical Diagram – 380-460V / 3PH / 50-60Hz Models without heater option

110-392 43

Electrical Diagram – 230V / 3PH / 50-60Hz Models with heater option

110-392 44

Electrical Diagram – 380-460V / 3PH / 50-60Hz Models with heater option

110-392 45

Options

110-392 46

4-20 mA Set Point Control

This feature is optional and may not appear in your version of the software.

NOTE: Two versions are available. If the model number of your Chiller contains a G in the 11

(e.g., 6860T56A26G 90°C; if the 11

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.

D), it provides 4-20mA set point control over a temperature range of 5° to

digit is an M, the 4-20mA control range is 4° to 40°C

“G” Models – 5° to 90°C Control

°C mA °F °C mA °F

5 6.4 41 50 13.6 122 10 7.2 50 55 14.4 131 15 8 59 60 15.2 140 20 8.8 68 65 16 149 25 9.6 77 70 16.8 158 30 10.4 86 75 17.6 167 35 11.2 95 80 18.4 176 40 12 104 85 19.2 185 45 12.8 113 90 20 194

“M” Models – 4° to 40°C Control

°C mA °F °C mA °F

4 4.00 39.2 23 12.44 73.4

5 4.44 41.0 24 12.89 75.2

6 4.89 42.8 25 13.33 77.0

7 5.33 44.6 26 13.78 78.8

8 5.78 46.4 27 14.22 80.6

9 6.22 48.2 28 14.67 82.4 10 6.67 50.0 29 15.11 84.2 11 7.11 51.8 30 15.56 86.0 12 7.56 53.6 31 16.00 87.8 13 8.00 55.4 32 16.44 89.6 14 8.44 57.2 33 16.89 91.4 15 8.89 59.0 34 17.33 93.2 16 9.33 60.8 35 17.78 95.0 17 9.78 62.6 36 18.22 96.8 18 10.22 64.4 37 18.67 98.6 19 10.67 66.2 38 19.11 100.4 20 11.11 68.0 39 19.56 102.2 21 11.56 69.8 40 20.00 104.0 22 12.00 71.6

digit

Manufactured by:

PolyScience

6600 W. Touhy Avenue Niles, IL 60714 U.S.A.

1-800-229-7569 ● 1-847-647-0611

www.polyscience.com

110-392 47

PolyScience DuraChill 1.5 HP Operating Manual

Specifications and Main Features

Frequently Asked Questions

User Manual