FTS MAXI-COOL, Operator'S Manual

Page 1: ...RECIRCULATING CHILLER OPERATOR S MANUAL MAXI COOL with EDC Control ...

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Page 3: ...tor s Manual by any means and in any form or manner is expressly prohibited except with the prior written permission of SP Scientific Permitted copies of this document must retain all proprietary notices contained in the original The information in this document is subject to change without prior notice Always confirm with SP Scientific that you are using the most current version of this document ...

Page 4: ...MENDATIONS STREAMLINE UNIT OPERATION AND PREVENT COMMON OPERATOR ERRORS WEAR SAFETY GLASSES EXPLOSIVE MATERIALS HAZARD KEEP OBJECTS AWAY FROM HEAT Safety Warnings Always transport the unit with care Sudden jolts or drops may damage the refrigeration system Always observe all warning labels Always turn off the unit and disconnect the line cord from the available power source prior to performing any...

Page 5: ...t or repair of parts pursuant to this warranty shall not in any way extend the original warranty period The Company shall not be responsible for any unauthorized repairs replacements or product modifications nor will it be responsible for any product failures resulting from such unauthorized repairs replacements or product modifications negligently or otherwise made by persons other than Company e...

Page 6: ...iv Rev 007 04 12 SP Scientific 2012 ...

Page 7: ...r Requirements 4 Electrical Requirements 5 Selecting a Process Fluid 6 General Properties of Process Fluids 7 Unit Check 8 Short Circuit Hose Hook Up 8 Removal of Panels 9 Installation 10 Add Fluid 10 Optional High Pressure Bypass Hook up 12 Connect to the Process 13 Prime the Fluid Loop 14 Operation 15 System Preparation 15 Basic Operation 15 Start Up 15 Control 16 Shut Down 16 High Pressure Bypa...

Page 8: ...30 Fuse Replacement 31 Cleaning 32 Draining Fluid 32 EDC Programmer s Reference 33 Overview 33 Hardware 33 Communications 34 Communication Data 34 Data Format 34 Received Data 34 Transmitted Data 36 Transmitted Data Format 38 Acknowledge 38 Error 38 Value 38 Terminator 39 Commands and Codes 39 Command Set 39 Alarm Codes 46 RS 232 Error Codes 47 Sample Program 50 Program 50 Appendix A Troubleshooti...

Page 9: ...P Scientific chillers feature innovative design high quality construction and highly dependable components This chiller will reliably serve your cooling needs for years to come THE MAXI COOL IS NOT INTENDED FOR USE WITH EXTREMELY FLAMMABLE FLUIDS SUCH AS ISOPENTANE C5H12 Key Features Small Footprint Digital RS 232 Control 0 1 C stability Wide Temperature Range Mechanical Refrigeration air or water...

Page 10: ...Introduction Maxi Cool 2 Rev 007 04 12 SP Scientific 2012 ...

Page 11: ...freight carrier immediately 1 Keep all contents packing material and related paperwork intact until a written report is obtained Note SP Scientific will cooperate in the matter of collecting your claim but is not responsible for the collection or free replacement of the material When possible replacement parts will be shipped and invoiced to you making them a part of your claim 1 Concealed damage ...

Page 12: ...l indoor environment Systems should not be mounted outside or otherwise exposed to the elements The environment should be free from air containing large amounts of moisture salt or sulfur If your system utilizes an air cooled condenser the fan in the system draws ambient air across the condenser radiator to cool the refrigerant Ambient Air Temperature Requirements 55 F to 69 F 12 C to 21vC Accepta...

Page 13: ...full load is applied to the receptacle Additionally the receptacle voltage should be measured while that receptacle is under load This unit has a NEMA 5 15P or 6 15P line cord install an appropriate NEMA 3 5 15R or 6 15R receptacle where the unit is to be run some 50 Hz machines are shipped with no plug Ensure the proper amperage circuit breaker is installed in the line and located 4 near the equi...

Page 14: ...d to speed troubleshooting it is suggested that one of the fluids mentioned above be used DO NOT USE AUTOMOTIVE ANTI FREEZE it contains clotting agents If for some reason one of the above fluids is not suitable and you select a different one be sure that it has a viscosity of less than 20 centistokes over the full temperature range of the unit Note All of the above mentioned fluids have viscosity ...

Page 15: ...sed from the fluid This release of gas should not be mistaken for boiling of the fluid Water Solubility 4 Process fluids are water soluble After long periods of operation at low temperatures water will mix with the fluid and decrease the performance of the system To remove the excess water warm the fluid to room temperature and pump the fluid through a molecular sieve or desiccant material Alterna...

Page 16: ...and output connections for the process fluid have 1 2 male pipe 1 threads on them Use a short hose 1 2 ID to connect the process fluid outlet directly to the 2 inlet This will allow the unit s functionality to be verified before connecting to your process Check that the drain is plugged and the drain valve is closed 3 ...

Page 17: ...12 9 SP Scientific 2012 Removal of Panels Ensure the power is turned off rocker switch to EMO O 1 Loosen and remove screws along edges of the panels 2 Pull off panels and place them out of the way 3 Place a piece of clean cardboard under the unit 4 ...

Page 18: ...sition the amber 4 POWER light should illuminate Press the I O button to start the unit 5 Use the buttons to adjust the display to 20 C 6 Run the unit continuously for 3 to 4 hours with the short circuit hose hooked up and the panels off If there are any fluid leaks in the system they will be highlighted by the 1 cardboard Also measure the wall voltage while the unit is running to be sure that it ...

Page 19: ...Maxi Cool Installation and Startup Rev 007 04 12 11 SP Scientific 2012 ...

Page 20: ...n The barb should face toward the back of the unit Long side of insulation goes down remember to use pipe thread sealant on all metal to metal connections 2 Thread Part 2 onto the process fluid input and tighten The opening should point toward right hand side of the machine operators right when looking at the control panel Long side of insulation goes down 3 Thread Part 3 onto Part 2 and tighten s...

Page 21: ... pipe thread1 2 ID tubing minimum Pipe Insulation Closed cell pipe insulation will work for most applications It can be purchased from any local refrigeration or plumbing supply house Glue seams of pipe insulation Polytetrafluoroethylene PTFE tape pipe sealant to seal all fittings If water cooled you will also need Water supply capable of 2 3 GPM and 30 60 Psi Any fittings and pipes necessary to m...

Page 22: ...it 4 CORROSIVE CHEMICAL WEAR SUITABLE GLOVES SAFETY GLASSES AND PROTECTIVE CLOTHING WEAR SAFETY GLASSES Add process fluid to reservoir until it is 1 2 5cm from the top 5 Replace lid 6 Press the I O button 7 When the reservoir drops to 1 3 full press the I O button to stop the pump 8 Remove the reservoir lid 9 Add fluid to reservoir until it is again 1 2 5cm from the top 10 Replace the reservoir li...

Page 23: ...e blank and the amber Power light will be illuminated 3 Basic Operation Start Up Press I O button 1 Display flashes SP setpoint then the current setpoint temperature the 2 setpoint is the temperature at which the unit will maintain the fluid temperature Adjust the Setpoint using the keys 3 Value for setpoint will be accepted after 4 seconds of inactivity 4 ...

Page 24: ...nsion contraction of the process fluid Once the chiller stabilizes at a setpoint tighten the red vent screw This will help prevent excess evaporation of the fluid as well as preventing atmospheric moisture from condensing on the fluid Shut Down Press the I O button to put the unit back in Idle 1 The refrigeration will shut down and the display will blank 2 The amber Power light will remain lit 3 M...

Page 25: ... High Pressure Bypass Adjustment If using a High Pressure Bypass take off the insulated valve cover as shown Use the brass T Handle to adjust the operating pressure of the system The pressure gauge on the front panel of the machine shows the system pressure ...

Page 26: ...Operation Maxi Cool 18 Rev 007 04 12 SP Scientific 2012 ...

Page 27: ...y High and Low Temperature Alarms Parameter Lock Setpoint Limits readout options Proportional Control parameters and several Communications options can all be adjusted from the User Menus The layout of the menus as well as the parameters contained in those menus is shown on the following pages They are navigated using the three buttons on the front panel of the EDC Controller The legends on the fo...

Page 28: ...ortional Control Menu 232 Communication Menu Etc Miscellaneous Menu SPAN Span Menu rr Ramp Rate LA Low Alarm PLOC Parameter Lock PAr Parity HA High Alarm It Integral Time rdyt Ready Time Const baud Baud Rate SH Span High dP Decimal Point CPb Cooling Band dAtA Word Length Cct Cool Cycle Time dt Derivative Time SL Span Low Sbit Stop Bit PF Power Fail Recovery dEg Temperature Scale rdy Ready Temp Ban...

Page 29: ...ered on the setpoint so a CPb of 5 degrees defines a window that s 2 5 degrees from the setpoint Integral Automatic Reset Time in seconds Is the time constant for adjustment of proportioning action that serves to correct deviations from setpoint Derivative Rate of Change adjustment Time in seconds Time constant for adjustment of proportioning action in order to reduce the slew rate of the process ...

Page 30: ...out removing the load In such an instance however the unit is incapable of supplying full cool and it is the responsibility of the user to correct the anomaly Span High Defines the maximum allowable setpoint Adjust the values of Span High and Span Low to define the range of setpoints acceptable for your particular application Span Low Defines the minimum setpoint in this range Low Alarm Same as HA...

Page 31: ...etpoint in degrees by which the system may be defined as ready The ready value 0 1 is normally available by means of a query to the chiller via the RS 232 Note Temperature operates in conjunction with the Ready Time described by the next parameter rdYt Ready Time Constant Ready Time Constant A time constant in seconds that the software uses to determine the ready condition A simple temperature ban...

Page 32: ... dAtA Word Length Sbit Stop Bit Stop Bit Parameter that may be selected 1 1 5 2 Data Word Length may be set to 7 bit or 8 bit Baud Rate For the RS 232 control communications port may be set according to the table Parity Detection may be selected per the following Note Data word 8 bit length forces no parity Display Parity 0 none 1 odd 2 even ...

Page 33: ...rogram Mode use the Up and Down buttons to move between 2 menu headings When PID is displayed press I O 3 Once inside a menu use the Up and Down buttons to adjust the value of 4 parameters The I O button accepts the value displayed and steps down to the next parameter in the menu After the last parameter has been stepped through you are returned to the 5 Operational Mode The following pages contai...

Page 34: ...ined in PID tuning CCt To determine the Cool Cycle Time CCt run the unit at the temperature that you wish the it to control best i e the setpoint The temperature will probably oscillate as the controller attempts to maintain temperature at the setpoint Watch the Cool Light Start a stopwatch when the Cool LED comes on wait for the LED to go off and stop the stopwatch when the temperature begins to ...

Page 35: ...etpoint 10 of that temperature swing Example CPb 2 C 10 of 2 C 2 0 2 2 2 Note New values for CPb are only processed with a new setpoint Therefore after entering new values for CPb it is necessary to get out of the Program Mode successive I Os ESC and change the setpoint Once in the Operation Mode change the setpoint press the key twice and then I O then you can change it back press the key twice a...

Page 36: ...User Menu Maxi Cool 28 Rev 007 04 12 SP Scientific 2012 ...

Page 37: ...CEDURES Note Always notify the SP Scientific Service Department before performing repairs to a unit that is under warranty Failure to notify SP Scientific Service will void the factory warranty Lockout Tagout Procedure To prevent accidental or unauthorized starting of this unit during maintenance disconnect the power cord and install an appropriate lockout device on the end of the power cord This ...

Page 38: ...Panel Removal of Panels Ensure the power is turned off move the breaker on the back of the unit to 1 the OFF position and push in the EMO on the front panel Loosen the screws along the back edge of the side panels 2 Pull off panels and place them out of the way 3 Front Panel ...

Page 39: ...Maxi Cool Maintenance Rev 007 04 12 31 SP Scientific 2012 Fuse Replacement Replace fuses only with the type and rating specified by the label on the inside of the panel Fuse Type and Rating Information ...

Page 40: ... bottom Let air settle for 6 several minutes and repeat Check for areas that have frosted during operation and insulate as required 7 Replace cabinet panels 8 Connect electric utilities 9 Draining Fluid The user may need to drain the unit for any number of reasons to replace the fluid to change the type of fluid used during maintenance during repairs etc Place a large low pan underneath the black ...

Page 41: ...orward as a program may be and will aid in locating the source of difficulty if this program runs successfully then the difficulty must be due to one of the extras or features of the unsuccessful driver Hardware The hardware of the RS 232 interface meets or exceeds the specifications of EIA standard RS 232 E 1991 with regard to electrical characteristics impedance open circuit characteristics volt...

Page 42: ...ible by the host i e an appropriate query by the host will result in a data stream returned from the system as defined below Data Format All data is transmitted in ASCII All data values are transmitted via decimal character strings Upper and lower case alphabetic characters will be accepted interchangeably Data descriptions are identified by direction from the perspective of the system controller ...

Page 43: ...ew Setpoint SP without all corresponding desired changes such as corresponding PID values All data received by the target system will be presented by the host system as a character string of one of the following formats Absolute Command 1 Basic system functions commands will consist of a fixed character string Examples START Wake up system STOP Shut down system POLL Force a response from the syste...

Page 44: ...ed below under Transmitted Data With few exceptions the query command replicates the mnemonic for the corresponding parametric command merely substituting the for the in the string Transmitted Data It is anticipated that in a remote controlled operation of the target system the actual controlling device may be either a computer with a software program or a human being working interactively The for...

Page 45: ...of full duplex operation i e it is capable of 5 receiving data while transmitting data However it is strongly suggested that the host wait for the message OK and the exclamation point before proceeding to its next transmission to ensure correlation between information sent and the replies The Command POLL has been provided as a non operative command similar to an assembly language NOP or BASIC lan...

Page 46: ...ue to a general error e g LINE TOO LONG the character trace code is 128 Example A Received string START 1 Transmitted string E030 0000128 CR 2 Error 30 Unit Not in Remote 3 Example B Received string SP 25 CPB 2 5 IT 35 0 DT 6 1 Transmitted message E021 0000019 CR 2 Error 21 Illegal character in position 19 3 Value The line begins with the character F Function followed by a 3 digit decimal code def...

Page 47: ... the interface Certain commands while syntactically acceptable to the parser will result in the error code Not Yet Implemented nyi these have been defined for future expansion or options The command opcode function F number which will be returned by a query appears in curly brackets following each query command Upper case is used to note other referenced commands ALARMH ALARMH F001 Set or query th...

Page 48: ...es of the band about setpoint SP over which the control system will proportion the cooling valves Cool Proportioning Band CTLREM CTLREM F011 Set or query the use of the remote sensor for temperature control of the system Value 0 off means control from the internal sensor 1 on means control from the remote sensor If the remote sensor is not connected open circuit the system will automatically rever...

Page 49: ...obsolete F020 Describes the format of transmitted data Task offloaded to the host processor FSPANH F021 Query the high temperature limit degrees established by the FLUID definition FSPANL F022 Query the low temperature limit degrees established by the FLUID definition GNREM GNREM F023 Adjust or query the calibration gain factor applied to the remote external temperature sensor GNRTD GNRTD F024 Adj...

Page 50: ... the LOCREM command may be asserted If set to 1 the LOCREM command will result in an error message LOCREM LOCREM F033 Set or query the local remote control status of the system If set to 0 the system may only be programmed from the local control panel If set to 1 the system may only be programmed from the remote communication link If the system is in local control LOCREM 0 all commands AAAAAAAA ex...

Page 51: ...tive command that may be used to test or synchronize the communications interface PT F043 Query the current process temperature as defined by the control point CTLREM PTLOC F044 Query the current local process temperature per the internal sensor PTREM F045 Query the current remote process temperature per the remote sensor PUMP F046 Query the status of the circulating pump 0 off 1 on PUMPSW PUMPSW ...

Page 52: ...d to turn the system on subject to positions of PUMPSW and REFRSW and to initiate the system temperature control software Query to determine whether the system is running 0 off 1 on STATUS Not implemented obsolete STOP Command to turn the system off restore displays and controls to idle SYSHOURS F063 Query number of running hours accumulated on the system as determined by the number of running hou...

Page 53: ...Implemented F071 Set or query the elapsed time to automatic wakeup WAKETIME WAKETIME Not Yet Implemented F072 Set or query the automatic wakeup time set via Real Time Clock option WINDOW WINDOW F073 Set or query the window in degrees used to determine process stability conformance to setpoint as reported by the system Alarm Ready contacts WINTIME WINTIME F074 Set or query the time constant in seco...

Page 54: ...e can be due to internal overtemp cutouts trip of a circuit breaker etc MPC Code 5 Stage 2 Refrigeration is not powered See Code 4 MPC Code 6 Pump is not powered May be not powered fuse may be blown etc MPC Code 7 System has been programmed for control from Remote sensor Remote sensor is open circuit MPC Code 8 EDC Code 3 High temperature alarm Process temperature exceeds ALARMH MPC Code 9 EDC Cod...

Page 55: ...ART detects loss of RS 232 line with host This error is only reported if such a break occurs after the receipt of valid data and before receipt of a CR carriage return Line break is otherwise ignored E005 Line Too Long Received line character string exceeds 128 characters without receipt of CR carriage return E006 Receive Buffer Overrun 1KB character input buffer is full Commands are being receive...

Page 56: ...characters E025 Illegal Sign Placement or Excess Decimal Points Polarity indication must be first character Only one decimal point permitted per number E026 Too Many Decimal Places Too many digits supplied after decimal point E027 Value Out of Bounds Programmed number exceeds limits fixed internally or by superseding limits e g FSPANH will limit USPANH E028 Excessive number The previous filters wi...

Page 57: ...ady stopped has received a STOP command E042 Start Error System already started has received a START command E043 Not a User Function Certain operational commands are defined to the system and reserved for factory use Error 43 reports use of such a command without proper security access E044 Local Lockout Unit is locked in local Removal of this lock may only be accomplished from the system control...

Page 58: ...send e g SP CR The character string returned by the MPC will be displayed on the user s terminal Users will note that the transmit receive strings appear to be out of synch on the terminal display this is also to keep the program as short and unencumbered as possible The Rubout Backspace and Delete keys will NOT work They will be transmitted like any other character and will result in an error mes...

Page 59: ...mal overload protection If it overheats the pump will shut down it will restart when the motor has cooled down This is usually a result of the pump being overworked Ensure that the viscosity of the fluid being used remains 20 centistokes Check solutions under Fluid Flow is Inadequate Pump motor has burned out This is very unlikely Check all possible causes above and if none of the solutions remedi...

Page 60: ...Open Sensor Measure resistance of sensor It should be approximately 100 ohms If it is not a new sensor is needed Contact SP Scientific Service for new sensor Connection on controller has come loose Check all connections on controller inside the unit If any are loose or disconnected reconnect them Low voltage to solenoid valves The controller is operating properly but because of inadequate voltage ...

Page 61: ...or must have adequate voltage to start Check voltage when power is applied to the system If voltage is not within 5 of the system rated voltage contact the electrical department to have the voltage corrected Refrigeration cutting out Ambient too warm The unit is designed for operation in an ambient environment of 72 F 22 C Temperatures over 80 F 27 C may cause the compressor to overheat Fan not wo...

Page 62: ...he overtemp is factory set for protection of the equipment DO NOT READJUST WITHOUT SP SCIENTIFIC SERVICE AUTHORIZATION Overtemp sensor open or not making good contact Verify that the heater is NOT getting AC Cooling valve sticking open Adjust the temperature set point to turn the cool indicator on off As the light alternates the valve clicks open close This should regulate the temperature at setpo...

Page 63: ...hiller the process equipment or the lines between In addition certain process fluids have extremely high coefficients of expansion Low temperatures can cause a dramatic drop in the overall volume Detection A float switch is installed in the reservoir If the level of the fluid drops below a critical level an alarm condition is triggered Action In either case the operator should conduct a close insp...

Page 64: ...hen either decrease the temperature setpoint to ensure it is set below the high temperature alarm setting HA or adjust the HA value so that it is above the desired setpoint If the HA still goes off check that the thermal load being applied by your process is within the heat removal capacity of this unit Contact the SP Scientific Service if the condition persists Low Fluid Temperature Report The di...

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Page 66: ...SP Scientific 815 State Route 208 Gardiner NY 12525 USA 3538 Main Street Stone Ridge NY 12484 USA www SPScientific com 800 431 8232 845 255 5000 ...