PolyScience DuraChill 2 to 3 HP Operating Manual

Operators Manual

DuraChill™ Air and Water Cooled 2 and 3 HP Chillers

110-275

1/7/10

Table of Contents

Section 1 – Safety and Warranty Information

1.1 Safety

1.2 Warranty

1.3 Unpacking

1.4 Contents

Section 2 – Description

2.1 General Description

2.2 Features - Standard and Optional

Section 3 – Chiller Specifications

3.1 Controller Specifications

3.2 Pump Performance

3.3 General Specifications

Section 4 – Installation and Startup

4.1 Site Requirements

4.2 Electrical Power

4.3 Optional Signal Inputs/Outputs

4.4 Plumbing

4.4.1 Air Cooled Units (DCA200 and DCA300)

4.4.2 Closed System or Cooling Coil Setup

4.4.3 Open Bath System Setup

4.5 Startup

4.5.1 Process Coolant

4.5.2 Filling the Reservoir

4.5.3 Starting Process Fluid Flow

Section 5 – Operation

5.1 Selecting the Temperature Unit (Cº or ºF)

5.2 Displaying and Adjusting the Set Point

5.3 Displaying and Adjusting the Ambient Tracking Offset

5.4 Selecting the Pressure / Flow Rate Display and Units

5.5 Setting Optional Parameters

5.5.1 High Temperature Limit (HL)

5.5.2 Low Temperature Limit (LL)

5.5.3 High Ambient Temperature Limit (HA)

5.5.4 Maximum Fluid Pressure (FP)

5.5.5 Minimum Flow Rate (FL)

5.5.6 Flow Rate Calibration

5.5.7 Auto-Refrigeration Temperature (AF)

5.5.8 Compressor Band

5.5.9 Ambient Tracking Probe (AP)

5.5.10 Calibration Offset (ºC)

5.5.11 Baud Rate (PC)

5.6 Serial Output (RS232 / RS485)

5.7 Display, Alarm, and Error Messages

5.8 Adjusting the High Pressure Bypass Setting

5.9 Enabling/Disabling Local Lockout

Section 6 – Maintenance and Calibration

6.1 Standard Magnetic Drive Centrifugal Pump

6.2 Condenser, Air Vents and Reusable Filter

6.3 Fluid Filter

6.4 Fluid Level

6.5 Calibration

Section 7 – Troubleshooting Section 8 - Service and Technical Support Appendix

A.1.1 Flow Diagram – Air-Cooled A.1.2 Flow Diagram – Water-Cooled A.2.1 Wiring Diagram – 208-230V, 1 Phase A.2.2 Wiring Diagram – 208-230V, 3 Phase A.2.3 Wiring Diagram – 380-460V, 3 Phase

Section 1 – Safety and Warranty Information

This symbol marks chapters and sections of this instruction manual which are particularly relevant to safety. When attached to the unit, this symbol draws attention to the relevant s ection of the instruction manual.

This symbol indicates that hazardous voltages may be present.

Read all instructions pertaining to safety, set-up, and operation.

Proper operation is the users’ responsibility.

1.1 Safety

It is the user’s responsibility to read and understand all instructions and safety precautions included in this manual prior to installing or operating this equipment. Contact our Customer Service Department with any questions regarding the operation of this chiller or the information contained in this manual.

Installation, operation, or maintenance of this equipment should be performed in strict 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.

Exercise care when unloading, loading, rigging, or moving this equipment.

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

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.

Always operate this equipment within the stated design specifications.

Be sure to remove power from the equipment, reclaim the refrigeration charge, and relieve any residual pressure before cutting into the refrigeration system.

Do not attempt to operate leaking or damaged equipment.

Service should only be performed by fully qualified personnel.

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

Do not attempt to override the power interlock switch or any other safety features on this equipment.

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

Do not move the equipment without first disconnecting power.

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

Additional Precautions

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

1.2 Warranty

Thank you for purchasing this chiller. We are confident it will serve you for a long time. Our warranty to you is as follows:

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

If this product requires service, contact the manufacturer/supplier's office for instructions. When return of the product is necessary, a return authorization number will be assigned and the product should be shipped, (transportation charges pre-paid), to the indicated service center. To insure prompt handling, the return authorization number should be placed on the outside of the package and a detailed explanation of the defect enclosed with the item.

This warranty shall not apply if the defect or malfunction was caused by accident, neglect, unreasonable use, improper service, or other causes not arising out of defects in material or workmanship. There are no warranties, expressed or implied, including, but not limited to, those of merchantability or fitness for a particular purpose which extends beyond the description and period set forth herein.

The manufacturer's sole obligation under this warranty is limited to the repair or replacement of a defective product and shall not, in any event, be liable for any incidental or consequential damages of any kind resulting from use or possession of this product. Some states do not allow: (A) limitations on how long an implied warranty lasts; or (B) the exclusion or limitation of incidental or consequential damages, so the above limitations or exclusions may not apply to you. This warranty gives you specific legal rights. You may have other rights that vary from state to state.

Warranty on Durachill and other custom-designed products apply only to the original end-user and cannot be transferred or sold to another end-user without written consent from the manufacturer.

1.3 Unpacking

Your chiller is shipped in a special container. Retain the container and all packing materials until the unit is completely assembled and working properly. Set up and run the unit immediately to confirm proper operation. If the unit is damaged or does not operate properly, contact the transportation company, file a damage claim and contact the company where your unit was purchased immediately.

1.4 Contents

— Recirculating Chiller — Operators Manual — Warranty Card

— Two sets of Inlet/Outlet Adapters, ¾ inch male NPT

Section 2 – Description

2.1 General Description

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.

2.2 Features - Standard and Optional

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 engineered 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 features, 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 high and low refrigerant pressure cutouts

• Process protection provided by over-temp/under-temp alarms

• Heavy-duty, locking casters provide easy maneuverability

• Magnetic Drive Centrifugal Pump (1/5 HP for DCA/W200, 1/3 HP for DCA/W300)

• Quick and easy installation with single-point power and ground wiring connections

• Power phase monitor on 2 and 3 HP

Optional

• Higher-output Centrifugal and Turbine pumps

• Ambient temperatures to 104°F

• Other process temperatures 5° to 185°F

• Process shutoff valves

• RS232 interface

• RS485 interface

Magnetic Drive Centrifugal Pump

• Tank sight glass or level indicator

• Remote temperature control probe

• Remote control panel

• Stainless steel reservoir

• High and low water pressure cutouts

• Audible and Visual Alarms

• Rail or foot mounting

• Tank low level indicator/alarm

• External water filter (side stream)

• Full flow bypass valve

• Digital LED Flow rate readout

• Auto water makeup valve

• DI compatible process piping

• Heaters

• 380V 3ph 50 Hz

• 200V 3ph 50Hz

• Alternate heat transfer fluids

A Configuration Data Sheet showing how your chiller is equipped is included with the documentation that accompanied this manual.

Section 3 – Chiller Specifications

3.1 Controller Specifications

Temperature Set Point Resolution ±1.0°C

Temperature Stability ±0.9°F / ±0.5°C

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

3.2 Pump Performance

8 0

7 0

6 0

5 0

Turbine Pump, 50 Hz

4 0

Pump curve, 2 Ton

Turbine pump, 60 Hz

3 0

Head pressure (PSI)

2 0

Magnetic Drive pump, 60 Hz

1 0

Magnetic Drive pump, 50 Hz

2 3 4 5 6 7 8

Fl ow ra te (GPM)

Pump Curve, 3 Ton

1 00

9 0

Turbine pump, 50 Hz

8 0

7 0

6 0

5 0

4 0

Head pressure, PSI

3 0

Magnetic Drive pump, 60 Hz

2 0

1 0

Magnetic Drive pump, 50 Hz

2 4 6 8 10 1 2 1 4

Fl o w ra te , GPM

Turbine pump, 60 Hz

DCA/W200

DCA/W300

3.3 General Specifications

2 HP

MODEL DCA200 DCW200

Compressor

Cooling Capacity

(1)

Nominal Evaporator Flow

Pressure

Pump Horse Power

(3)

PSIG 7.5 7.5

(3)

H.P. 1/5 1/5

Nom. HP

Tons

Watts

BTU/hr

(2)

USGPM 4.82 4.84

2 2

1.99

7000

23,885

2.02

7087

24,189

Fan(s) H.P. 2 @ 1/6 N/A

Condenser Discharge Air Flow CFM 2470 N/A

Water Condenser Flow-Tower Water US GPM N/A 6.05 (20-40 PSI)

Water Condenser Connections Inches N/A 3/4

Process Connections (To & From) Inches 3/4 3/4

Reservoir Tank Capacity US gallons 7 7

Dimensions (d x w x h) Inches 30.5 x 37 x 42 30.5 x 37 x 42

Shipping Weight Pounds 570 535

Temperature Range

Temperature Stability

°F °C

41° to 95°F

5°C to 35°C

± 0.9°F ± 0.5°C

41°F to 95°F

5°C to 35°C

± 0.9°F ± 0.5°C

460V/3/60 8.5 7.6

Nominal Rated Amps

230V/3/60

230V/1/60

Notes: 1. Capacity based on 68°F (20°C) entering air, and leaving water 68°F. Allowanc e made for heat gain from pump.

2. Chiller flow rate based on 2.4 USGPM/ton (0.54m3/hr/ton).

Specifications and dimensions subject to change without notice.

3. Based on standard magnetic drive centrifugal pump. Refer to pump performance charts for information on other pump types.

14 12.2

22 -

3 HP

MODEL DCA300 DCW300

Compressor

Cooling Capacity

Nominal Evaporator Flow

Pressure

Pump Horse Power

Fan(s)

Condenser Discharge Air Flow

Water Condenser Flow-Tower Water

Water Condenser Connections

Process Connections (To & From)

Reservoir Tank Capacity

Dimensions (d x w x h)

Shipping Weight

Temperature Range

Temperature Stability

(3)

(1)

(2)

(1)

Nom. HP

Tons

Watts

BTU/hr

USGPM

PSIG

H.P.

CFM

US GPM

Inches

US gallons

Inches

Pounds

°F °C

3 3

2.99

10,500

35,827

6.92 7.46

14 14

1/3 1/3

2 @ 1/6 N/A

2170 N/A

N/A 9.33 (20-40 PSI)

N/A 3/4

3/4 3/4

7 7

30.5 x 37 x 42 30.5 x 37 x 42

580 545

41° to 95°F

5°C to 35°C

± 0.9°F ± 0.5°C

3.11

10,936

37,326

41°F to 95°F

5°C to 35°C

± 0.9°F ± 0.5°C

460V/3/60

Nominal Rated Amps

Notes: 1. Capacity based on 68°F (20°C) entering air, and leaving water 68°F. Allowanc e made for heat gain from pump.

2. Chiller flow rate based on 2.4 USGPM/ton (0.54m3/hr/ton).

3. Based on standard magnetic drive centrifugal pump. Refer to pump performance charts for information on other pump types.

Specifications and dimensions subject to change without notice.

230V/3/60

230V/1/60

13.3 17.8

20 27.8

29 -

Section 4 – Installation and Startup

WARNING: Be sure all power is off before proceeding.

4.1 Site Requirements

Ambient Temperature and Relative Humidity

The Chiller is designed for indoor installation in ambient temperatures between 5° and 30°C (41° and 86°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 heatgenerating 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 outlet wired to meet the electrical data plate requirements. The use of an extension cord is not recommended.

Note: The Chiller may be located at a level below that of the equipment being cooled. As long as the process remains closed, overflow will not occur when adding cooling fluid to the Chiller reservoir.

Clearance

Adequate clearance should be allowed on the front, sides, and rear of the Chiller for access to connections and components. The front and rear vents of the Chiller must be a minimum of 24 inches (61 cm) away from walls or vertical surfaces so air flow is not restricted.

4.2 Electrical Power

Use the voltage and amperage requirements specified on the serial tag on the back of the unit. Total running amps for your unit are also found in the specification table in section 3.

Remove 3 screws securing top panel at rear. Remove top panel. Remove right side panel by pushing up from bottom to unhook latching tabs. Remove insulating cover over electrical compartment.

Bring properly sized power leads and ground from a fused disconnect (installed by a qualified electrician) to the unit. Use dual-element fuses in the disconnect switch, sized according to the National Electrical Code recommendations.

Connect proper phase sequence. You may want to turn power on to verify before putting the panels back on.

Make sure all electrical connections are tight.

– 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 the nameplate rating – Phase imbalance must be below 5%

With the chiller plugged in (before pressing the On button), the display responds by showing standby

(....). If there is no response, check that the circuit breaker on the rear of the chiller is in the ON

position. An extension cord is not recommended.

Caution!

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