Conair A1-1.5, User Manual

Page 1: ...www conairnet com The Conair Group Inc One Conair Drive Pittsburgh PA 15202 Phone 412 312 6000 Fax 412 312 6227 UGH017 0500 Installation Operation Maintenance Troubleshooting Portable Chillers Series...

Page 2: ...number s Model number s Power specifications Amps Volts Phase Cycle DISCLAIMER The Conair Group Inc shall not be liable for errors contained in this User Guide or for incidental consequential dam ages...

Page 3: ...nd Cautions 3 3 Preparing for Installation 3 4 Making Process Plumbing Connections 3 5 Filling the Chiller 3 6 Checking Refrigerant Charge 3 8 Connecting the Main Power Source 3 9 Checking Electrical...

Page 4: ...12 TROUBLESHOOTING 6 1 Before Beginning 6 2 A Few Words of Caution 6 3 Identify the Cause of a Problem 6 3 Answering Alarms 6 4 Control Problems 6 6 Alarm Conditions 6 8 Checking and Replacing Switch...

Page 5: ...Series 1 Portable Chillers PLC Control UGH017 0500 Purpose of the User Guide 1 2 How the Guide is Organized 1 2 Your responsibilities as a user 1 2 ATTENTION Read this so no one gets hurt 1 3 INTRODUC...

Page 6: ...onditions that could be hazardous to users or could damage equipment Read and take precautions before proceeding Numbers within shaded squares indicate tasks or steps to be performed by the user A dia...

Page 7: ...equipment at power levels other than what is specified on the machine serial tag and data plate WARNING Electrical hazard Before performing any work on this item dis connect and lock out electrical p...

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Page 9: ...0500 What is the Portable Chiller 2 2 Typical Applications 2 3 Limitations 2 3 How it Works Water cooled Portable Chiller 2 4 How it Works Air cooled Portable Chiller 2 6 Portable Chiller Features 2 8...

Page 10: ...d fill with water or with industrial grade ethylene glycol or propylene glycol but not automotive antifreeze These chillers are ideal for machine side cooling to maintain process temperatures in an in...

Page 11: ...LC Control DESCRIPTION 2 3 LIMITATIONS Conair Series 1 Portable Chillers are designed to provide chilled water for industrial applications requiring 24 hour a day performance Units are self contained...

Page 12: ...tion Pump draws water from pump reservoir and moves it through the strainer and flow switch to the evaporator 2 Hot fluid from the process enters the chiller through the From Process valve into the pu...

Page 13: ...or travels from the compressor through the coiled condenser where it is condensed into a liquid and is stored in the accumulator 3 Vaporized refrigerant travels from evapora tor to the compressor wher...

Page 14: ...ion Fluid is chilled in the evaporator and exits through the To Process valve and tube returning to the process 3 Hot fluid from the process enters the chiller through the From Process valve into the...

Page 15: ...back into the exaporator for the cycle to begin again 5 Vaporized refrigerant travels from evapora tor to the compressor where the low pressure vapor is compressed into a high pressure vapor 2 The liq...

Page 16: ...g erant from a low pres sure vapor into a high pressure vapor Hot Gas Bypass valve balances the load on the chiller to meet the needs of the process To Process connection TX valve regulates refrigeran...

Page 17: ...rocess fluid through the chiller Compressor compresses the refriger ant from a low pressure vapor into a high pres sure vapor TX valve regulates refrigerant flow Condenser compresses the refrigerant f...

Page 18: ...4 102 4 5 114 Weight lb kg Installed 420 190 585 265 585 265 840 381 840 381 1080 490 1090 494 1095 497 Shipped 550 249 755 342 755 342 1010 458 1010 458 1250 567 1260 572 1265 574 Utility requirement...

Page 19: ...9 10 2 38 6 14 5 54 9 21 0 79 5 26 3 99 6 Chilled water pressure psi bar 29 6 2 0 28 5 2 0 35 9 2 5 33 9 2 3 42 4 2 9 36 9 2 5 31 6 2 2 36 1 2 5 Reservoir capacity gal l 8 8 33 3 15 57 15 57 15 57 15...

Page 20: ...Series 1 Portable Chillers PLC Control UGH017 0500 2 12 DESCRIPTION PUMP CURVES Flow Rate gpm Pressure psi 60 HZ PUMP PERFORMANCE CURVES 50 HZ PUMP PERFORMANCE CURVES Pressure psi Flow Rate gpm...

Page 21: ...nstallation 3 4 Making Process Plumbing Connections 3 5 Filling the Chiller 3 6 Checking Refrigerant Charge 3 8 Connecting the Main Power Source 3 9 Checking Electrical Connections 3 10 Initially Star...

Page 22: ...e unit manu ally Carefully uncrate the chiller and its components Remove all packing material protective paper tape and plastic Compare contents to the shipping papers to ensure that you have all the...

Page 23: ...g on the Portable Chiller especially when working on or around the compressor and con denser These devices can reach up to 160 F 71 C Allow these devices to cool before per forming any maintenance or...

Page 24: ...ng a water cooled unit make sure condenser water source is plumbed to chiller installation location High points in plumbing require vent valves low points require drain valves Make sure the area where...

Page 25: ...Tighten only enough to prevent leaks do not over tighten Connect the To Process connection on the back of the chiller to the return hose Start by hand until the threads engage and then tighten with a...

Page 26: ...he chiller is overfilled the excess water spills out the vent tube DO NOT OVERFILL Close the Fill Drain valve Disconnect water hose from Fill Drain valve Series 1 Portable Chillers PLC Control UGH017...

Page 27: ...Drain valve Check the coolant level Once the chiller is turned on the coolant level may drop as the coolant begins to circulate filling the connected plumbing Check the coolant level on the back of t...

Page 28: ...esh side panel Use a flashlight if necessary and check the site glass Under full load conditions the refrigerant should be clear no bubbles Under low load conditions when the hot gas bypass valves are...

Page 29: ...s specified on the machine serial tag and data plate WARNING Electrical hazard Before performing any work on this item dis connect and lock out electrical power sources to prevent injury from unexpect...

Page 30: ...the grounding lug Test all three for resis tance The maximum resistance to ground should be 1 megohm If it resistance is more than 1 megohm there is a leak in the system WARNING Electrical hazard Befo...

Page 31: ...p is not turning disconnect main power to chiller swap any two wires reapply main power Check for leaks If you get an alarm message on the display If you get a Compressor Backwards Shut Off Swap Leads...

Page 32: ...ler from the main power supply Repair any leaks Dry any moisture inside the Chiller Reconnect the main power supply The Manual Pump screen displays 1 2 3 Before placing the Chiller into operation you...

Page 33: ...pump shuts off a few seconds later This allows the chiller to pump down the refrigerant system and store the refrigerant in the receiver This prolongs the life of the chiller NOTE If you want to rest...

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Page 35: ...ning Stopping the Chiller 4 5 Viewing Chiller Status 4 6 Programming Settings 4 8 Changing Setpoint Temperature 4 9 Resetting PID Settings 4 10 Changing High Temperature Deviation 4 11 Setting Percent...

Page 36: ...dis played on the screen Display screen shows status setup and run modes Up Down Scroll arrows scroll through the display screens Drop open bezel allows access for maintenance PLC Indicator lights sh...

Page 37: ...king process fluid level in the pump tank Checking the condenser coil for debris air cooled only Verifying pump discharge pressure Inspecting piping for leaks NOTE The daily weekly monthly and semi an...

Page 38: ...RUN ALM The main screen displays The main screen lets you view the status of the water level process temperature suction pressure percent glycol low temperature cutout and discharge pressure view and...

Page 39: ...ose PUMPDOWN Press the Escape Previous Screen button The control returns to the main screen 3 2 Select one If you disconnect the Chiller from the main power supply and reconnect it the Chiller needs 1...

Page 40: ...atus of the water level Screen displays Level Okay or Level Low If the level is low see Filling the Chiller in the Installation sec tion Temperatures displays the To Process temperature and the Setpoi...

Page 41: ...uction Pressure 70 PSIG Ref Discharge Pressure 250 PSIG Refrigerant Discharge pressure View the status of the refrigerant discharge pressure in PSIG Typical dis charge pressure is between 190 PSIG and...

Page 42: ...m Percent Glycol by Volume Use when you use an ethylene glycol or propylene gly col solution to lower the To Process temperature Changing the percent glycol automatically changes and displays the low...

Page 43: ...e in F flashes Press the arrows to change the setpoint temperature Pressing the arrow lowers the temperature by one degree pressing the arrow increases the tem perature by one degree Pressing the arro...

Page 44: ...from the main screen Press the Setup arrow Press the Scroll arrows to scroll through the Setup screens Stop when you get to the PID Reset screen Press the PID Reset arrow 3 2 1 STATUS SETUP RUN ALM P...

Page 45: ...deviation number displays along with the and The number flashes on the screen 1 STATUS SETUP RUN ALM press arrow Press the or arrows to set the high deviation to the appropriate number Each press of...

Page 46: ...n for the required temperature SETTING PERCENT GLYCOL NOTE If you are using water as the coolant set the Percent Glycol to zero on the control STATUS SETUP RUN ALM press arrow This screen is password...

Page 47: ...s for five minutes Otherwise press the Escape button to return to the Main screen Press the Scroll arrows to scroll to the next Setup screen or press the Escape Previous Screen button to return to the...

Page 48: ...e password Use the Keypad to enter the password and then press the Enter button The Fan Setpoint screen displays This screen is password protected You must have clearance to enter and change this sett...

Page 49: ...Portable Chillers PLC Control OPERATION 4 15 Press Enter to save the change 5 Press the scroll arrows to move to Fan 2 6 Repeat the steps for changing Fan 2 setpoint tempera tures Press the Escape Pre...

Page 50: ...the Auto Tune Mode from the main screen Press the Setup arrow This screen is password pro tected You must have clear ance to enter and change settings on this screen STATUS SETUP RUN ALM Press arrow...

Page 51: ...egins tuning This takes about 15 seconds When tuning the screen displays TUNE Tuning mes sage When tuning is complete the screen displays TUNE Normal message Press the Escape Previous Screen button to...

Page 52: ...P RUN ALM The first Run screen displays Use the Scroll arrows to scroll through Run screens to the Manual Pump screen Press the arrow pointing to your choice If the pump is running and you want to sto...

Page 53: ...Cautions 5 3 Preventative Maintenance Schedule 5 4 Entering Maintenance Screens 5 6 Checking Electrical Connections 5 8 Cleaning the Evaporator or Water cooled Condenser 5 9 Cleaning the Air cooled C...

Page 54: ...he time of the maintenance schedule depending on how often you use the chiller Among the features that require preventative maintenance are the refrigerant system electrical cables terminals and contr...

Page 55: ...in your region WARNING Electrical hazard Before performing any work on this item dis connect and lock out electrical power sources to prevent injury from unexpected energization or startup Be sure tha...

Page 56: ...ed Condensers in the Maintenance section Weekly or as often as needed Checking temperature and pressure readings Check the temperature and pressure display on the control screen and the pump pressure...

Page 57: ...Maintenance section Checking refrigerant charge Check the sight glass between the receiver and evapo rator to ensure it is clear with no bubbles See Checking Refrigerant Charge in the Maintenance sec...

Page 58: ...in hours Maintenance 3 4 To enter Maintenance screens requires security clearance There are two security levels built into the control let you limit access to the some setup and maintenance screens Th...

Page 59: ...4 Pump Run Time in hours 22 Pump Cycles 45 Hot Gas Bypass Cycles 31 Press the Escape Previous Screen button to exit the Maintenance screens and return to the main screen The password stays in effect f...

Page 60: ...power cord runs along the floor make sure it is positioned where it could not rest in pool ing water or could not be run over and cut by wheels or casters WARNING Electrical hazard Before performing...

Page 61: ...n the heat exchanger and reconnect the hose from the pump CLEANING THE EVAPORATOR OR WATER COOLED CONDENSER UGH017 0500 Series 1 Portable Chillers PLC Control MAINTENANCE 5 9 1 2 3 4 5 Acid solution F...

Page 62: ...ter supplied by Conair clean it using water or air Replace as needed CLEANING THE AIR COOLED CONDENSER Series 1 Portable Chillers PLC Control UGH017 0500 5 10 MAINTENANCE 1 2 3 WARNING Electrical haza...

Page 63: ...bypass valves are operating bubbles may be visible in the sight glass This is normal If the charge is low contact Conair service or have a local cer tified refrigeration technician to add refrigerant...

Page 64: ...er Because the Portable Chiller can use either pure water or a glycol solution make sure your are adding the correct fluid for your application CHECKING RESERVOIR LEVEL Series 1 Portable Chillers PLC...

Page 65: ...oblems 6 6 Alarm Conditions 6 8 Checking and Replacing Switches 6 16 Checking the Pressure Transducer 6 17 Checking the Temperature Transmitter and RTD 6 18 Replacing the RTD 6 20 Replacing the Temper...

Page 66: ...reference for correcting a problem The diagrams will note any custom features or options not covered in this User Guide Verify that you have all instructional materials related to the chiller Additio...

Page 67: ...ed by qualified technical person nel who are familiar with the construction oper ation and potential hazards of this type of machine All wiring disconnects and fuses should be installed by qualified e...

Page 68: ...5 Tmp 23 DP 40 SU 1 3 M To view any other alarms press the Scroll arrows ALM Alarm number DP Refrigerant dis charge pressure measured at the compressor outlet SU Refrigerant suction pressure measured...

Page 69: ...ow Fault Low Suction Pressure High Discharge Pressure Compressor Overload Pump Overload High Temperature Safety Low Temperature Cutout Description The fluid level in the pump tank is low There is low...

Page 70: ...main discon nect switch is on Check fuses and breakers Replace or reset as required See Replacing Fuses in the Troubleshooting section Check the voltage specification on the chiller nameplate Check f...

Page 71: ...Possible cause The input voltage is incorrect There is a phase loss Solution Check the main supply volt age It must be within 10 of the nameplate rating Check the fuses on the main power supply Repla...

Page 72: ...h Solution Fill tank to proper level See Checking Reservoir Level in the Maintenance section Inspect for leaks in the process piping Repair as necessary See Making Plumbing Connections in the Installa...

Page 73: ...ndicated on pump dis charge pressure gauge The evaporator is frozen Solution Open adjust valve s Clean the strainer Fill the reservoir See Making Process Plumbing Connections in the Installation secti...

Page 74: ...Check Flow switch and RTD Replace as needed Open valve Compare process load to required load Chiller may be oversized Clean Evaporator See Cleaning the Evaporator or Water cooled Condenser in the Main...

Page 75: ...d with refrig erant Faulty water regulating valve Faulty pressure transduc er Ambient air is over 95 F Solution Clean the coil See Cleaning the Air cooled Condenser in the Maintenance section Move chi...

Page 76: ...overload accord ingly Check supply voltage Supply voltage to contactor should be 10 of name plate voltage Check wire terminations and connections Tighten if loose Check line and load side of contacto...

Page 77: ...overload accord ingly Check supply voltage Supply voltage to contactor should be 10 of name plate voltage Check wire terminations and connections Tighten if loose Check line and load side of contacto...

Page 78: ...to the Hot Gas Bypass solenoid If the To Process temperature starts to go down the solenoid valve is faulty Have a certified refrig eration technician replace the solenoid valve Large swings in proce...

Page 79: ...ure Transmitter RFI interference may have altered PLC Solution If the To Process temperature starts to go down the solenoid valve is faulty Have a certified refrigeration technician replace the soleno...

Page 80: ...nection for the correct switch on the terminal switch Refer to the wiring diagrams you received with your chiller to find the correct terminals Check the switch Check continuity within the switch and...

Page 81: ...e exact location Check the control signal in the electrical panel if the supply voltage is correct step 3 Refer to the wiring diagram for the exact location If the signal is out side the 0 5 4 5 VDC r...

Page 82: ...ing diagram Find the temperature sensor in the evaporator Check the wiring and connections from the sensor to the temperature transmitter electrical box Turn the power on to the chiller control Check...

Page 83: ...tance Check RTD with ohmmeter Should be close to 100 ohms Disconnect black lead and place current meter in series Check RTD with current meter Current should be 4 20 mA Inspect for condensation Dry wi...

Page 84: ...RTD wiring from the transmitter electrical box Refer to the wiring diagram Remove the RTD Loosen the compression nut to slide the RTD out of the evaporator Install the new RTD The new RTD should be i...

Page 85: ...n the side of the chiller Disconnect the RTD wiring from the transmitter electrical box Refer to the wiring diagram Disconnect transmitter wiring from main electrical panel Remove the temperature tran...

Page 86: ...e side of the chiller Remove the bolts connecting the pump assembly to the pump housing Remove the pump assembly Carefully slide it sideways away from the pump tank to avoid damage Inspect clean and r...

Page 87: ...re Locate the overload module and disconnect the power leads from the module to the device Refer to the wiring diagram for the exact location Note the place ment of each lead and label as needed Disco...

Page 88: ...rtable Chillers PLC Control UGH017 0500 6 24 TROUBLESHOOTING Always refer to the wiring diagrams you received with your chiller to locate specif ic electrical components WARNING Electrical hazard Befo...

Page 89: ...wire so you can correctly install the new unit Remove the contactor by snapping off the DIN rail mounting Snap in the new contactor on the DIN rail Reconnect the wiring and reconnect power to the chi...

Page 90: ...enclosure as a single unit Place new PLC into position Tighten the screws to hold the PLC in place Replace connectors The PLC is preprogrammed at the factory You can tell if the PLC is programmed if i...

Page 91: ...ollowing checklist before calling Conair Make sure you have all model serial and parts list numbers for your particular equipment Service personnel will need this information to assist you Make sure p...

Page 92: ...one of the following options Inspect the equipment and perform alterations or adjustments to satisfy performance claims Charges for such inspections and corrections will be waived unless failure to me...

Page 93: ...rge Pressure Suction pressure Evaporator water out temperature Process Water Pressure In Out Condenser Water Temperature In Out Condenser Water Pressure In Out Condenser Fan Amps 1 Condenser Fan Amps...

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Page 95: ...BLES UGH017 0500 Series 1 Portable Chillers PLC Control APPENDIX C 1 Evaporator and Piping Pressure Drops Flow Rate GPM Pressure Drop PSID A1 W1 10 A1 13 A1 W1 5 W1 15 A1 W1 3 A1 W1 4 A1 W1 7 5 A1 W1...

Page 96: ...500 APPENDIX C 2 0 10 10 20 20 30 30 40 40 50 50 60 60 70 70 80 80 0 5 10 10 15 20 25 30 30 35 40 40 45 45 50 55 55 Condenser and Piping Pressure Drops PRESSURE TABLES Pressure Drop PSID Flow Rate GPM...

Page 97: ...emove burrs sharp edges ream pipe cuts and make joints air tight 5 Don t spring pipe to make connections Strain must not be transmitted to pump 6 Allow for pipe expansion with hot fluids expansion joi...

Page 98: ...rain pump remove all liquid from the casing 2 Keep fluid moving in pump and insulate or heat the pump to prevent freezing If heated do not let temperature go above 100 to 150 degrees F 3 Fill pump com...

Page 99: ...ake sure the lapped faces are clean 5 Hold shaft against rotation as described in paragraph 8 of disassembly procedure and thread impeller on shaft until it is tight against the shaft shoulder The imp...

Page 100: ...e rubber drive band on the rotary head until the lapped face on the head seats firmly against the lapped face of the stationary seat Do not chip or scratch faces during installation Take extra care to...