PolyScience DuraChill 58 Series, DuraChill 68SS Series, DuraChill 69 Series, DuraChill 59 Series User Manual
User Guide
DuraChill Air- and Water-Cooled 1.5 HP Chillers
27 June 2016
110-392
Table of Contents
Introduction ...............................................................................................................................................................3
General Safety Information .....................................................................................................................................3
Safety Recommendations .......................................................................................................................................3
Regulatory and Compliance Testing ...................................................................................................................5
Contents .................................................................................................................................................................5
Controls and Components ......................................................................................................................................6
Control Panel .......................................................................................................................................................6
Front ....................................................................................................................................................................6
Rear -- 230V, 240V, and 208-230V Units ...........................................................................................................7
Rear -- 380V and 460V Units ..............................................................................................................................7
Quick Start .................................................................................................................................................................8
Installation and Startup ............................................................................................................................................9
Site Requirements ...................................................................................................................................................9
Ambient Temperature and Relative Humidity .....................................................................................................9
Location ...............................................................................................................................................................9
Clearance ............................................................................................................................................................9
External Piping ..................................................................................................................................................... 10
General Considerations .................................................................................................................................... 10
Process Fluid Connections ............................................................................................................................... 11
Facility Water Connections ............................................................................................................................... 11
Reservoir Drain................................................................................................................................................. 11
Reservoir Vent .................................................................................................................................................. 11
Process Coolant ................................................................................................................................................... 12
Electrical Power ................................................................................................................................................... 13
Phase Requirements (if applicable) ................................................................................................................. 13
Optional Signal Inputs/Outputs ............................................................................................................................ 13
Ambient / External Temperature Probe ............................................................................................................ 13
RS-232/RS-485 Serial Output .......................................................................................................................... 13
Remote On / Off Port ........................................................................................................................................ 13
4-20mA Set Point Control ................................................................................................................................. 13
Startup .................................................................................................................................................................. 14
Facility Water Flow (water-cooled units only) ................................................................................................... 14
Filling the Reservoir .......................................................................................................................................... 14
Starting Process Fluid Flow .............................................................................................................................. 14
Normal Operation .................................................................................................................................................. 15
Selecting the Temperature Unit ........................................................................................................................... 15
Displaying and Adjusting the Set Point ................................................................................................................ 15
Selecting the Internal / External Temperature Display ........................................................................................ 15
Displaying and Adjusting the Ambient Tracking Offset ........................................................................................ 16
Displaying and Adjusting the Remote Control Temperature ............................................................................... 16
Selecting the Pressure / Flow Rate Display and Units ........................................................................................ 16
Setting Operational Parameters / Limits .............................................................................................................. 17
Display, Alarm and Error Messages .................................................................................................................... 20
Adjusting the High Pressure Bypass Setting ..................................................................................................... 22
Enabling / Disabling the Local Lockout .............................................................................................................. 22
Over-Temperature Protection ............................................................................................................................... 23
Routine Maintenance............................................................................................................................................. 24
Routine Maintenance ........................................................................................................................................... 24
Condenser, Air Vents and Reusable Filter ....................................................................................................... 24
Inline Strainer ................................................................................................................................................... 24
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Fluid Level ........................................................................................................................................................ 24
Cleaning ........................................................................................................................................................... 24
Temperature Calibration ....................................................................................................................................... 25
Internal Calibration Offset (c1) ............................................................................................................................. 25
External Calibration Offset (c2) ............................................................................................................................ 25
Flow Rate Calibration (Fc) .................................................................................................................................... 26
Fuse Bits (Fb) ......................................................................................................................................................... 26
Troubleshooting .................................................................................................................................................... 27
Diagnostic Mode .................................................................................................................................................. 28
Technical Information ........................................................................................................................................... 29
Controller Specifications ...................................................................................................................................... 29
Performance Specifications ................................................................................................................................. 29
Electrical Specifications ....................................................................................................................................... 30
Pump Performance .............................................................................................................................................. 31
RS-232 / RS-485 Communications ....................................................................................................................... 32
Certificate of Compliance ..................................................................................................................................... 33
Equipment Disposal (WEEE Directive) ................................................................................................................ 33
Service and Technical Support ............................................................................................................................ 33
Replacement Parts .............................................................................................................................................. 34
Pumps .................................................................................................................................................................. 35
Warranty ................................................................................................................................................................. 36
Appendix ................................................................................................................................................................ 37
Flow Schematic - All Models ................................................................................................................................ 37
Electrical Diagram – 208-230V / 1PH / 50-60 Hz Models without heater option ................................................. 38
Electrical Diagram – 208-230V / 1PH / 50-60Hz Models with heater option ....................................................... 39
Electrical Diagram – 208-230V and 380-460V / 3PH / 50-60Hz Models without heater option .......................... 40
Electrical Diagram - 208-230V and 380-460V / 3 PH / 50-60Hz Models with heater option ............................... 41
Options ................................................................................................................................................................. 42
General Options Wiring .................................................................................................................................... 42
RS-485 Communications Wiring ...................................................................................................................... 42
DI Control Wiring .............................................................................................................................................. 43
H2 & H3 Option Wiring ..................................................................................................................................... 43
4-20 mA Set Point Control ................................................................................................................................ 44
..............
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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.
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 a wide range of potential dangers. When attached to the unit, consult the operator's
manual.
This symbol advises danger from electricity or electric shock.
This symbol indicates that a hot surface may be present.
This symbol marks information that is particularly important.
This symbol indicates alternating current.
/
These symbols on the Power Switch / Circuit Breaker indicate that they place the main power supply ON / OFF.
This symbol on the Power Key (if present) 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 questions
regarding the operation of this Chiller or the information contained in this manual.
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: Always operate the unit within the stated temperature and pressure design specifications.
WARNING: All warning labels should be carefully observed. Never remove or obstruct a warning label.
WARNING: Units which use cooling fluid must be properly filled before use and properly drained before
moving or service. Allow reservoir fluid to return to ambient temperature before draining. Be sure to follow
your organization's procedures and practices regarding the safe lifting and relocation of heavy objects.
For items weighing 18 kg or more, safe practice lifting should be performed by at least two people.
WARNING: Service should only be performed by fully qualified personnel. Extreme caution is required as
hazards are present when servicing this equipment.
WARNING: Do not attempt to operate leaking or damaged equipment.
CAUTION: Be sure to follow all appropriate safety and environmental guidelines when collecting and
disposing of spent coolant.
WARNING:
Do not plug unit into the electrical outlet until it is ready for startup.
Always connect the power cord on this unit to a grounded power outlet. Make certain that the outlet is the
same voltage and frequency as your unit (see identification label). Never operate the unit with a damaged
power cord.
Always turn the unit OFF and disconnect mains power before performing any maintenance or service as
hazardous voltages exist within chassis components.
WARNING: Make sure the equipment's main power switch is in the OFF position before connecting or
disconnecting electrical power from the unit. Follow all applicable electrical and safety codes and
procedures when connecting power to the unit. Electrical connections should be made by an authorized
electrical installer.
WARNING: Disconnect electrical power before moving the unit. Keep unit upright when moving. Follow
your company's procedures and practices regarding the safe lifting and relocation of heavy objects. For
items weighing 18 kg or more, safe practice lifting should be performed by at least two people.
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Regulatory and Compliance Testing
Canada USA (60Hz) units
CAN/CSA C22.2 No. 61010-1-12 – Safety Requirements for Electrical Equipment for Measurement, Control and Laboratory
Use, Part I: General Requirements.
CAN/CSA C22.2 No. 61010-2-010-04 (R2014) – Safety Requirements for Electrical Equipment for Measurement, Control
and Laboratory Use – Part 2-010: Particular Requirements for Laboratory Equipment for the Heating of Materials.
UL Std No. 61010-1 (2012) – Safety Requirements for Electrical Equipment for Measurement, Control and Laboratory Use –
Part 1: General Requirements.
UL Std No. 61010-2-010 (2015) – Safety Requirements for Electrical Equipment for Measurement, Control and Laboratory
Use – Part 2-010: Particular Requirements for Laboratory Equipment for the Heating of Materials.
CE (50Hz units)
Machinery Directive 2006/42/EC
EC Electromagnetic Compatibility Directive 2014/30/EU
IEC 61010-1 / EN 61010-1:2010
IEC 61010-2-010 / EN 61010-2-010:2014
IEC 61326:2012 / EN 61326:2013
RoHS Directive 2011/65/EU
Australia/New Zealand (50 Hz)
ACMA – Radiocommunications (Electromagnetic Compatibility) Standard 2008 EN 61326-1:2013
EAC Customs Union (50 Hz)
TP TC 010/2011 On Safety of Machinery and Equipment
TP TC 004/2011 On Safety of Low Voltage Equipment
TP TC/020/2011 Electromagnetic Compatibility of Technical Equipment
Highly Accelerated Life Test (HALT) and Vibration Tests per ASTM D4169-8 (All units)
Contents
The following items have been included with your Chiller:
• Operator’s Manual
• Two sets of Inlet/Outlet Adapters: ½ inch male NPT x ½ inch hose barb and ½ inch male NPT x 5/8 inch hose
barb (select models)
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Controls and Components
Reservoir Cap
Pressure / Flow
Rate Display
Pressure / Flow
Rate Units
Unit / Menu Select Button
Air Filter
Temperature Display
Select / Set Knob
Power Button
Temperature Units
Control Panel
Bypass Valve Access Panel
Air Filter Access
Ambient / External
Temperature Tracking
Probe
(optional)
Control Panel
Front
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Connection
Rear – 230V, 240V, and 208-230V Units
Communications Port (optional)
RS-232 Port (optional)
Remote Temperature
Probe Port (optional)
Power Switch / Circuit Breaker
Reservoir Vent
(Vent Assembly required
on 5XXX models)
Fluid Inlet (from process)
Fluid Outlet (to process)
Facility Water Outlet
(water
Facility Water Inlet
cooled models)
Reservoir Drain
Over-Temperature
Protection Adjust
(5XXX models only)
Over-Temperature Protection
Reset (5XXX models only)
Vent Assembly
(supplied with
5XXX models)
Electrical Connections
Junction Box
Power Switch
(water-
Rear – 380V and 460V Units
-cool models)
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Quick Start
See Installation & Startup for additional information.
All units:
Connect process lines
1
2
3
4
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
5
6
7
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Turn Controller ON
Add coolant to reservoir as
process lines fill
Enter temperature set point
Installation and Startup
Site Requirements
Ambient Temperature and Relative Humidity
The Chiller is designed for indoor installation in ambient temperatures between 16° and 35°C (60° and 95°F);
relative humidity should not exceed 80% (non-condensing).
Location
Install the Chiller on a strong, level surface as close to possible to the process requiring cooling. It should not be
installed closer than 4 feet (1.4 meters) to a heat-generating source. If possible, the unit should be located near a
suitable drain to prevent flooding in the event of leaks. Do not place it where corrosive fumes, excessive moisture,
excessive dust, or high room temperatures are present.
Position the Chiller as close as possible to the power distribution panel. Avoid voltage drops by using a properly
grounded power source wired to meet electrical data plate requirements. The use of an extension cord is not
recommended.
NOTE: The unit may be located at a level below that of the equipment being cooled. As long as the process
remains closed, overflow will not occur when adding cooling fluid to the unit's reservoir.
Clearance
Allow adequate clearance on the front, sides, and rear of the Chiller for access to connections and components.
The front and rear vents of the Chiller must be a minimum of 24 inches (61 cm) away from walls or vertical
surfaces so air flow is not restricted.
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External Piping
Facility Water Outlet
Facility Water Inlet
Reservoir Drain
Reservoir Vent
(shown with Vent
Assembly for
5XXX models))
Process Fluid Inlet
Process Fluid Outlet
General Considerations
It is the user’s responsibility to ensure that the tubing and fittings connected to the Chiller are compatible with the
fluid, temperature, and pressure being used.
• All external piping, tubing, or hoses should be run full size to limit the potential for external pressure drops.
The use of quick-connect fittings is not recommended, as they can cause substantial pressure drops.
• Materials of construction should be compatible with the fluid being used as well as the temperature and
pressure at which the unit will operate.
• Where applicable, always use a back-up wrench when making piping connections to the Chiller.
• Pressure Ratings – Hoses should be able to withstand the highest pressure that they will encounter (100 psi
/ 6.9 bar).
• Flexible Tubing – Avoid tubing that will expand and increase fluid volume when operating at the desired
pressure.
• Hose Diameter – The fittings on the Chiller’s process fluid lines are female 0.5 in NPT. The facility water fluid
inlets and outlets on water-cooled models are female 0.75 inch NPT.
• Facility Water (water-cooled models only) – Should be clean and well maintained. Ideally, the facility water
should be tested monthly to ensure a pH level between 7.2 and 7.8. Add algaecide if algae growth is
present.
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Process Fluid Connections
The incoming cooling water pressure should be 20 psi / 1.4 bar minimum and 150 psi / 10.3 bar
The Chiller has two internally threaded fittings on the rear of the instrument housing for the process water
connections. Two sets of adapters are supplied with the unit for connecting these fittings to the process piping.
The direction of the flow through the system can be controlled by the way the connections are made. Fluid is
drawn into the Chiller through the “Inlet” connection; fluid is pumped out of the Chiller through the “Outlet”
connection.
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: On units requiring facility water, those connections must be made by a licensed plumber.
CAUTION:
maximum.
Water-cooled Chillers have two internally threaded fittings 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 connection is provided for the reservoir’s gravity drain.
Reservoir Vent
A reservoir vent assembly is provided with Chillers equipped with the heater option to relieve pressure within the
reservoir as coolant heats and expands. A connection is provided on the rear of the Chiller for the vent assembly.
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Process Coolant
Suitable Fluids
WARNING: For units that use cooling fluids.
Use only fluids that comply with safety, health, and equipment compatibility requirements. Read the safety
data sheet for the fluid being used carefully before use.
CAUTION: DO NOT USE
Caustic, corrosive, or flammable liquids
Automotive anti-freeze*
Hard tap water*
Deionized water with a specific resistance >1 meg ohm
Concentrations of acids or bases
Solutions with halides: chlorides, fluorides, bromides, iodides, or sulfur
Chlorine bleach
Glycerine
Syltherm fluids
At temperatures above 40°C, additives or mineral deposits can adhere to the heater. If deposits are allowed to build up,
*
the heater may overheat and fail. Higher temperatures and higher concentrations of additives will hasten mineral
deposits
The Chiller can accommodate a variety of coolant fluids (water, glycol mixtures, etc). For most applications above 20°C (68°F),
distilled water is satisfactory. For operation below 20°C (68°F), the Chiller must be protected with an antifreeze solution.
Ethylene glycol (laboratory grade) and water in a 50/50 mixture is satisfactory from +20° to -15°C (68° to 5°F). Select a fluid
that is compatible with the Chiller’s wetted parts (brass, bronze, stainless steel, EPDM rubber, nylon, PVC).
WARNING: Operation below 20°C (68°F) requires antifreeze in the circulation fluid. Do not use automotive
antifreeze as the additives may be harmful to the Chiller's wetted parts.
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