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