Troubleshooting
Series 1 Water-CooledW1 and
Air-CooledModels A1 with TIC Control
Installation Operation Maintenance
Model numbers Power specifications Amps Volts
Phase Cycle
Date Manual Number UGH016/0500 Serial numbers
TABLE OF CONTENTS
INTRODUCTION
DESCRIPTION
TABLE OF CONTENTS
MAINTENANCE
TROUBLESHOOTING
PARTS AND DIAGRAMS . . . . . . . . . . . .P/D-1
Your responsibilities as a user
INTRODUCTION
Purpose of the User Guide
How the guide is organized
PURPOSE OF THE USER GUIDE
HOW THE GUIDE IS ORGANIZED
YOUR RESPONSIBILITY AS A USER
READ THIS SO NO ONE GETS HURT
WARNING Electrical hazard
CAUTION Hot Surfaces
CAUTION Ventilation hazard
Page
DESCRIPTION
WHAT IS THE PORTABLE CHILLER?
Cooling load
TYPICAL APPLICATIONS
Temperature
LIMITATIONS
HOW IT WORKS WATER-COOLED PORTABLE CHILLER
Process circulation
DESCRIPTION
CONT’D
Refrigerant circulation
HOW IT WORKS
WATER-COOLED
DESCRIPTION
HOW IT WORKS AIR-COOLED PORTABLE CHILLER
HOW IT WORKS
AIR-COOLED PORTABLE CHILLER
DESCRIPTION
CHILLER FEATURES
PORTABLE
Water-cooledModels
Air-cooledModels
PORTABLE CHILLER FEATURES
Weight lb kg
SPECIFICATIONS
2-10
Dimensions in mm
MODEL
Dimensions in mm
Weight lb kg
DESCRIPTION
50 HZ PUMP PERFORMANCE CURVES
PUMP CURVES
2-12
60 HZ PUMP PERFORMANCE CURVES
INSTALLATION
CAUTION Lifting hazard
UNPACKING THE BOXES
WARNINGS AND CAUTIONS
CAUTION Hot Surfaces
CAUTION Ventilation hazard
PREPARING FOR INSTALLATION
A grounded power source
Available water source
MAKING PROCESS PLUMBING CONNECTIONS
3 Wrap threads with Mylar or Teflon tape
Connect the To Process valve and tubing on
Close the Fill/Drain valve
FILLING THE CHILLER
Attach water hose to Fill/Drain valve
Open the Fill/Drain valve and fill chiller
Close the Fill/Drain valve
Change the minimum operating temperature
FILLING THE CHILLER
Open the Fill/Drain valve and fill chiller
CHECKING REFRIGERANT CHARGE
WARNING Refrigerant hazard
Sight glass
WARNING Electrical hazard
CONNECTING THE MAIN POWER SOURCE
2 Connect the power wires to the terminals
4 Connect the ground wire to grounding lug
WARNING Electrical hazard
CHECKING ELECTRICAL CONNECTIONS
3-10
5 Turn on main power source
2 Press the Start Chiller button
INITIALLY STARTING THE CHILLER
1 Turn on main power source
WARNING Initial startup
3-12
STOPPING THE CHILLER
Changing Temperature Scale
OPERATION
TIC Control Features
Changing Settings
OPERATION
TIC CONTROL FEATURES
Checking process fluid level in the pump tank
BEFORE STARTING
WARNING Electrical hazard
Checking electrical connections
Press the Start Chiller button
STARTING STOPPING THE CHILLER
Temperature Scale
CHANGING SETTINGS
CHANGING THE SETPOINT TEMPERATURE
Temperature Setpoint
3 Press the Up/Down arrows
CHANGING TEMPERATURE SCALE
CHANGING TO AUTO TUNE MODE
2 Press the Enter button
6 Press Enter button
CHANGING AUTO TUNE MODE
4 Press the Menu button
5 Use the Up/Down arrows to change
3 Press the Up/Down arrows
SETTING THE TO PROCESS LOW LIMIT
MAINTENANCE
MAINTENANCE FEATURES
WARNING: Refrigerant hazard
WARNING AND CAUTIONS
WARNING Electrical hazard
CAUTION Hot Surfaces
Checking electrical connections
PREVENTATIVE MAINTENANCE SCHEDULE
Daily, or as often as needed
Weekly, or as often as needed
Cleaning the tank and float switch
PREVENTATIVE MAINTENANCE SCHEDULE
Cleaning
Cleaning process fluid strainer
WARNING Refrigerant hazard
CHECKING THE REFRIGERANT CHARGE
piping with fresh water after cleaning
CLEANING THE EVAPORATOR OR WATER-COOLED CONDENSER
1 Prepare a 5% solution of Phosphoric acid
Back-flushthe solution through the
WARNING: Electrical hazard
CLEANING THE AIR-COOLED CONDENSER
Clean the dirty coils with a soft brush
coil cleaner
CHECKING ELECTRICAL CONNECTIONS
1 Be sure the main power is disconnected
3 Inspect all wires and connections
5 Inspect the exterior power cords
WARNING Electrical hazard
CHECKING RESERVOIR LEVEL
5-10
Disconnect and lockout power to the chiller
TROUBLESHOOTING
WARNING: Refrigerant hazard
BEFORE BEGINNING
A FEW WORDS OF CAUTION
WARNING Electrical hazard
TIME
IDENTIFYING THE CAUSE OF A PROBLEM
Compressor
ANSWERING AN ALARM
Alarm Condition
Pump
Power is not reaching the chiller
CONTROL PROBLEMS
Symptom
Solution
There is a phase loss
CONTROL PROBLEMS
Symptom
Solution
Failed Level switch
MECHANICAL CONDITIONS
Alarm
Solution
main power leads to the pump
Alarm
Solution
Switch any two of the three
Faulty overload module
Possible cause Solution
Alarm
Faulty contactor
Faulty overload module
Alarm
SOLUTION
Faulty contactor
MECHANICAL CONDITIONS
Alarm
Solution
Specifications in the
Faulty pressure switch
Alarm
Solution
Faulty water regulating valve
The pressure switch is
Alarm
Solution
failed flow switch and
MECHANICAL CONDITIONS
Symptom
Solution
Contact Conair Service
4 Replace the switches as needed
CHECKING AND REPLACING SWITCHES
1 Disconnect and lockout power to the chiller
3 Check the switch
Reconnect the wiring and reconnect power
REPLACING THE CONTACTOR
Disconnect and lockout power to the chiller
Disconnect the wiring from the contactor
7 Install the new RTD
CHECKING AND REPLACING THE
1 Disconnect and lockout power to the chiller
5 Disconnect the RTD wiring from the
4 Contact Conair Service for the temperature
REPLACING THE TEMPERATURE CONTROLLER
1 Disconnect and lockout power to the chiller
2 Snap the Temperature Controller board out
6 Install the new module
REPLACING OVERLOAD MODULES
1 Disconnect and lockout power to the chiller
4 Disconnect auxiliary wiring to the module
WARNING Electrical hazard
REPLACING FUSES
Disconnect and lockout power to the chiller
Restore power to the chiller
Inspect, clean, and replace pump parts
REMOVING PUMP COMPONENTS
Remove the bolts connecting the pump
Remove the pump assembly
Check the control signal in the electrical panel
CHECKING PRESSURE SWITCHES
TIME
Locate the pressure switch
Description
CHECKING PRESSURE SWITCHES
4 Check the continuity within the switch
CONT’D
Page
BEFORE YOU
WE’RE HERE TO HELP
HOW TO CONTACT CUSTOMER SERVICE
CALL
EQUIPMENT GUARANTEE PERFORMANCE WARRANTY
WARRANTY LIMITATIONS
A-2 SERVICE INFORMATION WARRANTY INFORMATION
Condenser Water Temperature, In/Out
MAINTENANCE LOG
Date Maintenance Item
Suction pressure Evaporator water out temperature
Page
TABLES
Evaporator and Piping
PRESSURE
Pressure Drops
W1-1.5
PRESSURE
TABLES
APPENDIX C-2
Parameter
CONTROL SETTINGS
Setting
Display
Page
P/D-1
PARTS & DIAGRAMS
RECOMMENDED SPARE PARTS
P/D-2
Part Number Description
RECOMMENDED SPARE PARTS
Part Number Description
Motor Starter Protector 20.0-25.0A
20973003 Flowtect, Flow Switch, Evap Circuit
RECOMMENDED SPARE PARTS
Part Number Description
RECOMMENDED SPARE PARTS
Part Number Description
29213105 TXV 2 ton Water- and Air-cooled
RECOMMENDED SPARE PARTS
Part Number Description
Condenser Fan Motor, 1/2HP, 575V, 60Hz, for A1-7.5