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