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