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Conair MPA, MPW manual

Models: MPW MPA

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Contents

Page Date Manual Number UGH004/0999 Serial numbers Model numbers TABLE OF CONTENTS INSTALLATIONMAINTENANCE INTRODUCTIONPARTS/DIAGRAMS MAINTENANCE . . . . . . . . . . . . . . .continuedTROUBLESHOOTING DIAGNOSTICSYour responsibilities as a user ATTENTION Read this so INTRODUCTIONPurpose of the User Guide How the guide is organized no one gets hurtPURPOSE OF THE USER GUIDE HOW THE GUIDE IS ORGANIZEDYOUR RESPONSIBILITY AS A USER WARNING Electrical shock hazard READ THIS SO NO ONE GETS HURTPage Specifications Water-cooled Specifications Air-cooled What is the microKool chiller? Typical applications How it worksWater-cooled models How it works Air-cooled models Features DESCRIPTIONWHAT IS THE MICROKOOL CHILLER?TYPICAL APPLICATIONS HOW IT WORKS WATER COOLED HOW IT WORKS AIR COOLED Typical air-cooled plumbing diagramMolded Plastic Reservoirs FEATURESHigh Efficiency Compressors Water ConnectionsWeight lb kg SPECIFICATIONS MPW WATER COOLEDDimensions inches mm SPECIFICATION NOTESDimensions inches mm SPECIFICATIONS MPA AIR COOLEDPerformance characteristics SPECIFICATION NOTESto Process Set Temperature, degrees F Freeze Protection Requirements by Unit Set TemperatureFreezing Points of Aqueous Ethylene Glycol Solutions Ethylene Glycol, % by weightConnecting the water supply Connecting the main power INSTALLATIONUnpacking the boxes Preparing for installation Testing the installation Entering setpoint deviation parametersYou are now ready to begin installation UNPACKING THEBOXES Install plumbing for process and cooling lines PREPARING FOR INSTALLATIONMake sure the installation area provides 1 Position the chiller as close to the process machine as possibleTools for installation CONNECTING PROCESS AND WATER SUPPLY LINES2 Install pipe to the rear of the chiller 1 Remove the shipping pipe plug from the femaleIMPORTANT! Before initiating power to the unit CONNECTING THE MAIN POWER SUPPLY4 Connect the power wires to the terminals 1 Open the unit’s electrical enclosureApply power to the unit TESTING THE INSTALLATIONshould perform this procedure Replace the access panelENTERING SETPOINT DEVIATION PARAMETERS INITIAL SETUP Dip switch ConfigurationWARNING Electric shock hazard Change Dip Switch 1 to CHANGING TEMPERATURE UNITSDisconnect and lock out main power to the Open the electrical enclosureand switches 5 and Disconnect and lock out main power to the unitSet dip switch 3 to ON Close the electrical enclosure and restorePress the RUN button to save the passcode Set dip switch 3 to OFFClose the electrical enclosure and restore power to the unit Open the electricalSet dip switches 3 and SELECTING THE TEMPERATURE CONTROL POINTDisconnect and lockout power to the unit Set dip switch 5 to theINSTALLATION Press the RUN button to save the control pointSELECTING THE TEMPERATURE CONTROL POINT the main power supply3-14 INSTALLING THE AUTO START FEATURE4 Insert the two power leads from the device IMPORTANT Always6 Set dip switch 4 to the ON position FEATUREINSTALLING THE When Auto Start is enabled3-16 2 Apply power to the chiller 3 Enter the passcode, if necessaryACTIVATING SPI COMMUNICATION 1 Connect the host machine to the chillerOPERATION PC-1 control features PC-2 control featuresStarting the chiller Stopping the chiller Using the PC-2 pumpdown Positioning the control panel Entering a passcodeSetpoint adjustment buttons PC-1 CONTROL FEATURESAlarm Setpoint displaySetpoint adjustment buttons PC-2 CONTROL FEATURESPumpdown On/Off AlarmTo lower the control panel POSITIONING THE CONTROL PANELTo raise and swivel the control panel To detach the PC-2 control panelENTERING A PASSCODE Press again to enter the passcodePress Setpoint to select the parameter you want to change 3 Turn on the water supply to the chiller MPW STARTING THE CHILLER2 Make sure the chiller tank is full of fluid 4 Enter the passcodeTo shut down the unit 1 Press Stop USING THE PUMPDOWN FEATURESTOPPING THE CHILLER Press theDisconnect and lock out main power to the unit Enable Auto Tune4 Restore power to the unit PERFORMING AN AUTO TUNEInsufficient setpoint/process deviation PERFORMING AN AUTO TUNEb a d Invalid PID constants were generatedPage output monitors Calibrating temperature sensors MAINTENANCEMaintenance schedule Cleaning evaporators Cleaning condensers Filling the tank Checking refrigerant charge Performing system testsPREVENTATIVE MAINTENANCE SCHEDULE 5-2 MAINTENANCEQuarterly every 3 months Annually every 12 monthsPREVENTATIVE MAINTENANCE SCHEDULE To clean the evaporator CLEANING EVAPORATORSCLEANING CONDENSERS cleaning chemicalsREFILLING THE TANK Locate the fill port at 2 the back of the chillerDESCRIPTION section for information on glycol mix- tures CHECKING REFRIGERANT CHARGE If the charge is low, recharge the systemPERFORMING SYSTEM TESTS Set dip switches 3 andSet dip switch 6 to ON then open the electrical enclosurePress any key Enable Test ModeKEY/DISPLAY TEST Press any key to clear all displaysPress any key to display the first test menus INPUT TESTConnect all inputs to the system Select the Input Test menuConnect all outputs to the system OUTPUT TEST5-10 Select the Output Test menuPress the Setpoint to select the next output Select the OM Enable/Disable menuDISABLING OR ENABLING OUTPUT MONITORS Save changes and exit the output menu5-12 CALIBRATING TEMPERATURE SENSORS1 Enable Test Mode Release the Setpoint keyPress Select 6 Press the up key to begin calibrating7 Wait until the control displays “don” or “bad.” 9 Exit Calibration ModeIndex through test menus to the operating log LOGGING OPERATING HOURS5-14 Exit the Operating Hours Logof a problem TROUBLESHOOTINGBefore beginning A few words of caution How to identify the cause Shut down alarms Warning alarms System alarmsIf an alarm is present, note any indicator lights Before you begin troubleshootingFind the wiring, plumbing and other diagrams BEFORE BEGINNINGA problem can trigger three types of alarms HOW TO IDENTIFYTHE CAUSE OF A PROBLEM When an Alarm condition occursAlarm Possible cause SolutionSHUT DOWN ALARMS Hi SAFSHUT DOWN ALARMS Lo SAFPossible cause Solution AlarmSHUT DOWN ALARMS PHS ErrPossible cause Solution AlarmAlarm Possible cause SolutionSHUT DOWN ALARMS Is the overload faulty or set incorrectly?Alarm SHUT DOWN ALARMSPossible cause Solution Refrigerant pressure is either too low or too highAlarm SHUT DOWN ALARMSPossible cause Solution GPM=2.4 x chiller ton capacityWARNING ALARMS Possible cause SolutionAlarm Cause SYSTEM ALARMSSolution ERR ERR6-12 CHILLER WILL NOT POWER UPSymptom Possible cause SolutionTo replace a blown fuse Disconnect and lockout the main powerCHECKING AND REPLACING FUSES If fuses continue to failDisconnect auxiliary wiring on the overload module RESETTING OVERLOADS1 Disconnect and lockout the main power Set the module reset mode to M for manualSet dip switches 7 and 8 to the correct unit type Disconnect and lockout the main power supply9 Reconnect the terminal blocks and wires to the new board REPLACING THE MOTHERBOARDREPLACING THE COMPRESSOR CONTACTOR Reverse this procedure to install the new conDisconnect the wires from the compressor con 6-161 Clear any alarms and restart the chiller 2 Watch for the following CHECKING THE UNLOADER VALVEReverse the process to install the new unit. Be Disconnect and lockout the power supplyDisconnect freezestat unit wires from their ter REPLACING THE FREEZESTATBEFORE YOU HOW TO CONTACT CUSTOMER SERVICEWE’RE HERE TO HELP From outside the United States, callEQUIPMENT GUARANTEE PERFORMANCE WARRANTY WARRANTY LIMITATIONS APPENDIX A-2SPI COMMANDS SUPPORTED BY THE CONAIR MICROKOOL SPI Command PairsAPPENDIX B-1 APPENDIX B-2 SPI STATUS WORDSStatus, Process CHILLER SPI COMMANDSCHILLER SPI COMMANDS Status, MachineAPPENDIX B-3 SPI STATUS WORDSSPI STATUS WORDS APPENDIX B-4CHILLER SPI COMMANDS Status, MachinePC-2 Wiring Diagram . . . . . . . .PD-4 PARTS/DIAGRAMSPC-1 Wiring Diagram . . . . . . . .PD-2 Parts Lists . . . . . . . . . . . . . . . .PD-6PD-2 PC-1 WIRING DIAGRAMUGH004/0999 PC-1 CIRCUIT BOARD PD-3PC-1 CIRCUIT BOARD JUMPERPD-4 PC-2 WIRING DIAGRAMUGH004/0999 PC-2 CIRCUIT BOARD PD-5PC-2 CIRCUIT BOARD JUMPER