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Date Manual Number UGH004/0999 Serial numbers Model numbers
INSTALLATION
MAINTENANCE
TABLE OF CONTENTS
INTRODUCTION
MAINTENANCE . . . . . . . . . . . . . . .continued
TROUBLESHOOTING
PARTS/DIAGRAMS
DIAGNOSTICS
INTRODUCTION
Purpose of the User Guide How the guide is organized
Your responsibilities as a user ATTENTION Read this so
no one gets hurt
HOW THE GUIDE IS ORGANIZED
PURPOSE OF THE USER GUIDE
YOUR RESPONSIBILITY AS A USER
WARNING Electrical shock hazard
READ THIS SO NO ONE GETS HURT
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What is the microKool chiller? Typical applications How it works
Water-cooled models How it works Air-cooled models Features
Specifications Water-cooled Specifications Air-cooled
DESCRIPTION
CHILLER?
WHAT IS THE MICROKOOL
TYPICAL APPLICATIONS
HOW IT WORKS WATER COOLED
HOW IT WORKS AIR COOLED
Typical air-cooled plumbing diagram
FEATURES
High Efficiency Compressors
Molded Plastic Reservoirs
Water Connections
SPECIFICATIONS MPW WATER COOLED
Dimensions inches mm
Weight lb kg
SPECIFICATION NOTES
SPECIFICATIONS MPA AIR COOLED
Performance characteristics
Dimensions inches mm
SPECIFICATION NOTES
Freeze Protection Requirements by Unit Set Temperature
Freezing Points of Aqueous Ethylene Glycol Solutions
to Process Set Temperature, degrees F
Ethylene Glycol, % by weight
INSTALLATION
Unpacking the boxes Preparing for installation
Connecting the water supply Connecting the main power
Testing the installation Entering setpoint deviation parameters
UNPACKING THE
You are now ready to begin installation
BOXES
PREPARING FOR INSTALLATION
Make sure the installation area provides
Install plumbing for process and cooling lines
1 Position the chiller as close to the process machine as possible
CONNECTING PROCESS AND WATER SUPPLY LINES
2 Install pipe to the rear of the chiller
Tools for installation
1 Remove the shipping pipe plug from the female
CONNECTING THE MAIN POWER SUPPLY
4 Connect the power wires to the terminals
IMPORTANT! Before initiating power to the unit
1 Open the unit’s electrical enclosure
TESTING THE INSTALLATION
should perform this procedure
Apply power to the unit
Replace the access panel
ENTERING SETPOINT DEVIATION PARAMETERS
Dip switch Configuration
INITIAL SETUP
WARNING Electric shock hazard
CHANGING TEMPERATURE UNITS
Disconnect and lock out main power to the
Change Dip Switch 1 to
Open the electrical enclosure
Disconnect and lock out main power to the unit
Set dip switch 3 to ON
and switches 5 and
Close the electrical enclosure and restore
Set dip switch 3 to OFF
Close the electrical enclosure and restore power to the unit
Press the RUN button to save the passcode
Open the electrical
SELECTING THE TEMPERATURE CONTROL POINT
Disconnect and lockout power to the unit
Set dip switches 3 and
Set dip switch 5 to the
Press the RUN button to save the control point
SELECTING THE TEMPERATURE CONTROL POINT
INSTALLATION
the main power supply
INSTALLING THE AUTO START FEATURE
4 Insert the two power leads from the device
3-14
IMPORTANT Always
FEATURE
INSTALLING THE
6 Set dip switch 4 to the ON position
When Auto Start is enabled
2 Apply power to the chiller 3 Enter the passcode, if necessary
ACTIVATING SPI COMMUNICATION
3-16
1 Connect the host machine to the chiller
PC-1 control features PC-2 control features
Starting the chiller Stopping the chiller Using the PC-2 pumpdown
OPERATION
Positioning the control panel Entering a passcode
PC-1 CONTROL FEATURES
Alarm
Setpoint adjustment buttons
Setpoint display
PC-2 CONTROL FEATURES
Pumpdown On/Off
Setpoint adjustment buttons
Alarm
POSITIONING THE CONTROL PANEL
To raise and swivel the control panel
To lower the control panel
To detach the PC-2 control panel
Press again to enter the passcode
ENTERING A PASSCODE
Press Setpoint to select the parameter you want to change
STARTING THE CHILLER
2 Make sure the chiller tank is full of fluid
3 Turn on the water supply to the chiller MPW
4 Enter the passcode
USING THE PUMPDOWN FEATURE
STOPPING THE CHILLER
To shut down the unit 1 Press Stop
Press the
Enable Auto Tune
4 Restore power to the unit
Disconnect and lock out main power to the unit
PERFORMING AN AUTO TUNE
PERFORMING AN AUTO TUNE
b a d
Insufficient setpoint/process deviation
Invalid PID constants were generated
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MAINTENANCE
Maintenance schedule Cleaning evaporators Cleaning condensers
output monitors Calibrating temperature sensors
Filling the tank Checking refrigerant charge Performing system tests
PREVENTATIVE MAINTENANCE SCHEDULE
5-2 MAINTENANCE
Annually every 12 months
Quarterly every 3 months
PREVENTATIVE MAINTENANCE SCHEDULE
CLEANING EVAPORATORS
CLEANING CONDENSERS
To clean the evaporator
cleaning chemicals
Locate the fill port at 2 the back of the chiller
REFILLING THE TANK
DESCRIPTION section for information on glycol mix- tures
CHECKING REFRIGERANT CHARGE
If the charge is low, recharge the system
Set dip switches 3 and
Set dip switch 6 to ON
PERFORMING SYSTEM TESTS
then open the electrical enclosure
Enable Test Mode
KEY/DISPLAY TEST
Press any key
Press any key to clear all displays
INPUT TEST
Connect all inputs to the system
Press any key to display the first test menus
Select the Input Test menu
OUTPUT TEST
5-10
Connect all outputs to the system
Select the Output Test menu
Select the OM Enable/Disable menu
DISABLING OR ENABLING OUTPUT MONITORS
Press the Setpoint to select the next output
Save changes and exit the output menu
CALIBRATING TEMPERATURE SENSORS
1 Enable Test Mode
5-12
Release the Setpoint key
6 Press the up key to begin calibrating
7 Wait until the control displays “don” or “bad.”
Press Select
9 Exit Calibration Mode
LOGGING OPERATING HOURS
5-14
Index through test menus to the operating log
Exit the Operating Hours Log
TROUBLESHOOTING
Before beginning A few words of caution How to identify the cause
of a problem
Shut down alarms Warning alarms System alarms
Before you begin troubleshooting
Find the wiring, plumbing and other diagrams
If an alarm is present, note any indicator lights
BEFORE BEGINNING
HOW TO IDENTIFY
THE CAUSE OF A PROBLEM
A problem can trigger three types of alarms
When an Alarm condition occurs
Possible cause Solution
SHUT DOWN ALARMS
Alarm
Hi SAF
Lo SAF
Possible cause Solution
SHUT DOWN ALARMS
Alarm
PHS Err
Possible cause Solution
SHUT DOWN ALARMS
Alarm
Possible cause Solution
SHUT DOWN ALARMS
Alarm
Is the overload faulty or set incorrectly?
SHUT DOWN ALARMS
Possible cause Solution
Alarm
Refrigerant pressure is either too low or too high
SHUT DOWN ALARMS
Possible cause Solution
Alarm
GPM=2.4 x chiller ton capacity
Possible cause Solution
WARNING ALARMS
Alarm
SYSTEM ALARMS
Solution
Cause
ERR ERR
CHILLER WILL NOT POWER UP
Symptom
6-12
Possible cause Solution
Disconnect and lockout the main power
CHECKING AND REPLACING FUSES
To replace a blown fuse
If fuses continue to fail
RESETTING OVERLOADS
1 Disconnect and lockout the main power
Disconnect auxiliary wiring on the overload module
Set the module reset mode to M for manual
Disconnect and lockout the main power supply
9 Reconnect the terminal blocks and wires to the new board
Set dip switches 7 and 8 to the correct unit type
REPLACING THE MOTHERBOARD
Reverse this procedure to install the new con
Disconnect the wires from the compressor con
REPLACING THE COMPRESSOR CONTACTOR
6-16
1 Clear any alarms and restart the chiller 2 Watch for the following
CHECKING THE UNLOADER VALVE
Disconnect and lockout the power supply
Disconnect freezestat unit wires from their ter
Reverse the process to install the new unit. Be
REPLACING THE FREEZESTAT
HOW TO CONTACT CUSTOMER SERVICE
WE’RE HERE TO HELP
BEFORE YOU
From outside the United States, call
EQUIPMENT GUARANTEE PERFORMANCE WARRANTY WARRANTY LIMITATIONS
APPENDIX A-2
SPI Command Pairs
SPI COMMANDS SUPPORTED BY THE CONAIR MICROKOOL
APPENDIX B-1
SPI STATUS WORDS
Status, Process
APPENDIX B-2
CHILLER SPI COMMANDS
Status, Machine
APPENDIX B-3
CHILLER SPI COMMANDS
SPI STATUS WORDS
APPENDIX B-4
CHILLER SPI COMMANDS
SPI STATUS WORDS
Status, Machine
PARTS/DIAGRAMS
PC-1 Wiring Diagram . . . . . . . .PD-2
PC-2 Wiring Diagram . . . . . . . .PD-4
Parts Lists . . . . . . . . . . . . . . . .PD-6
PC-1 WIRING DIAGRAM
PD-2
UGH004/0999
PD-3
PC-1 CIRCUIT BOARD
PC-1 CIRCUIT BOARD
JUMPER
PC-2 WIRING DIAGRAM
PD-4
UGH004/0999
PD-5
PC-2 CIRCUIT BOARD
PC-2 CIRCUIT BOARD
JUMPER