Conair UGH016/0500 - Manuals

Page 2 - Power specifications:; Please record your

It’s a good idea to record the model and serial number(s) ofyour equipment and the date you received it in the UserGuide. Our service department uses this information, alongwith the manual number, to provide help for the specificequipment you installed. Please keep this User Guide and all manuals, e...

Page 3 - ABLE OF; NTRODUCTION

UGH016/0500 Series 1 Portable Chillers, TIC Control T ABLE OF C ONTENTS I NTRODUCTION . . . . . . . . . . . . . . . . . . .1-1 Purpose of the User Guide . . . . . . . . . . . . . . . . . . . . . . . . .1-2How the Guide is Organized . . . . . . . . . . . . . . . . . . . . . . .1-2Your Responsibilitie...

Page 4 - AINTENANCE; ii

Series 1 Portable Chillers, TIC Control UGH016/0500 T ABLE OF C ONTENTS M AINTENANCE . . . . . . . . . . . . . . . . . . . .5-1 Maintenance Features . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-2Warnings and Cautions . . . . . . . . . . . . . . . . . . . . . . . . . . .5-3Preventative Ma...

Page 5 - ATTENTION: Read this so

1-1 Series 1 Portable Chillers, TIC Control UGH016/0500 ● ● 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 I NTRODUCTION

Page 7 - EAD THIS SO NO

UGH016/0500 Series 1 Portable Chillers, TIC Control I NTRODUCTION 1-3 We design equipment with the user’s safety in mind. You canavoid the potential hazards identified on this machine by fol-lowing the procedures outlined below and elsewhere in theUser Guide. ATTENTION: R EAD THIS SO NO ONE GETS HUR...

Page 9 - ESCRIPTION

2-1 Series 1 Portable Chillers, TIC Control UGH016/0500 ● ● 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-coo...

Page 10 - All standard voltages are available.; HAT IS THE

The Conair Series 1 Portable Chillers provide self-containedsources of chilled water and are available in either water- orair-cooled models, ranging in sizes from 3.5 Hp to 40 Hp(approximate capacities of 3.5 tons of refrigeration to 40 tonsof refrigeration). Pump selections are available to match m...

Page 11 - IMITATIONS; Cooling load

The Conair A1 and W1 Portable Chillers can be used any-where a reliable source of process cooling water - with stabletemperature control - is required. These portable chillers are available for cooling injectionmolding, blow molding, thermoforming, extrusion, air com-pressors, metal plating, anodizi...

Page 13 - OW IT; CONT; Refrigerant circulation

UGH016/0500 Series 1 Portable Chillers, TIC Control D ESCRIPTION 2-5 The evaporator extracts heat from the process fluid, caus- ing the refrigerant to vaporize(evaporate) into a gas. 1 Vaporized refrigeranttravels from evapora- tor to the compressor,where the low pressurevapor is compressed intoa hi...

Page 16 - ORTABLE

Series 1 Portable Chillers, TIC Control UGH016/0500 2-8 D ESCRIPTION P ORTABLE C HILLER F EATURES Receiver stores the liquid refrigerant. Filter dryer cleans and dries the refrig-erant. From Process valve Relief valve acts as a safetydevice for refrig-erant pressure. Condenser compresses therefriger...

Page 18 - PECIFICATIONS

Series 1 Portable Chillers, TIC Control UGH016/0500 2-10 D ESCRIPTION Water-cooled Models S PECIFICATIONS front side back B A C D E F 10 {254} 9 {229} 10.5 {267} 5.5 {140} MODEL W1-1.5 W1-2 W1-3 W1-4 W1-5 W1-7.5 W1-10 W1-15 Performance characteristicsCapacity ✝ tons 1.44 1.93 3.23 4.44 5.00 7.09 10....

Page 20 - UMP

Series 1 Portable Chillers, TIC Control UGH016/0500 2-12 D ESCRIPTION P UMP C URVES Flow Rate (gpm) Pressure (psi) 60 HZ PUMP PERFORMANCE CURVES 50 HZ PUMP PERFORMANCE CURVES Pressure (psi) Flow Rate (gpm)

Page 21 - Making Process Plumbing; NSTALLATION

3-1 Series 1 Portable Chillers, TIC Control UGH016/0500 ● ● Unpacking the Boxes . . . . . . . . . .3-2 ● ● Warnings and Cautions . . . . . . . . .3-3 ● ● Preparing for Installation . . . . . . .3-4 ● ● Making Process Plumbing Connections . . . . . . . . . . . . . . . .3-5 ● ● Filling the Chiller . ....

Page 22 - The portable chiller comes fully assembled in a single crate.; NPACKING THE; CAUTION: Lifting hazard

The portable chiller comes fully assembled in a single crate. U NPACKING THE B OXES Series 1 Portable Chillers, TIC Control UGH016/0500 3-2 I NSTALLATION CAUTION: Lifting hazard The Series 1 Portable Chillers are designed toeasily roll on casters. If, for some reason youneed to lift the chiller, tak...

Page 23 - ARNINGS AND

WARNING: Improper installation, oper-ation, or servicing may result in equip-ment damage or personal injury. This equipment should only be installed, adjust-ed, and serviced by qualified technical person-nel who are familiar with the construction, oper-ation, and potential hazards of this type ofmac...

Page 24 - Plan the location for the chiller and prepare the area properly.; A grounded power source.

P REPARING FOR I NSTALLATION Series 1 Portable Chillers, TIC Control UGH016/0500 3-4 I NSTALLATION Plan the location for the chiller and prepare the area properly. Position the Chiller as close to the process machine as possi-ble. Place the chiller in position near the process machine sothat fluid l...

Page 25 - AKING; Remove the shipping plastic pipe plug from; the female connections on the back of the portable chiller.; Make sure the male pipe threads are clean

UGH016/0500 Series 1 Portable Chillers, TIC Control I NSTALLATION 3-5 M AKING P ROCESS P LUMBING C ONNECTIONS Warm fluid from your process enters the chiller at the FromProcess valve and chilled fluid returns to the process equip-ment through the To Process valve. Remove the shipping plastic pipe pl...

Page 26 - ILLING THE; Close the To Process and From Process valves.; To fill with glycol solution:; Mix the glycol to the proper percentage.

Series 1 Portable Chillers, TIC Control UGH016/0500 3-6 I NSTALLATION F ILLING THE C HILLER The Chiller is shipped without coolant. The chiller is filledmanually during installation. Use water as the coolant down to40 °F (4 °C). Below 40 °F and down to 20 °F (-7 °C), use anethylene glycol or propyle...

Page 27 - Setting the To Process Low Limit,

UGH016/0500 Series 1 Portable Chillers, TIC Control I NSTALLATION 3-7 Temperature of Process Fluid ° F Gl ycol, % b y V olume Close the To Process and From Process valves. Open the Fill/Drain valve and fill chiller to the fill mark on the Water Level gauge. If the chiller isoverfilled, the excess fl...

Page 28 - Under normal load conditions, the refrigerant should; WARNING: Refrigerant hazard

C HECKING R EFRIGERANT C HARGE Series 1 Portable Chillers, TIC Control UGH016/0500 3-8 I NSTALLATION All chillers are fully charged with refrigerant at the factory.Your chiller’s model nameplate identifies the type and amountof total refrigerant charge required. Check refrigerant charge while the ch...

Page 29 - WARNING: Electrical hazard

C ONNECTING THE M AIN P OWER S OURCE UGH016/0500 Series 1 Portable Chillers, TIC Control I NSTALLATION 3-9 WARNING: Improper installation, oper-ation, or servicing may result in equip-ment damage or personal injury. This equipment should only be installed, adjust-ed, and serviced by qualified techni...

Page 30 - Open electrical enclosure.; to the main line connection.; Close the electrical enclosure.

C HECKING E LECTRICAL C ONNECTIONS Series 1 Portable Chillers, TIC Control UGH016/0500 3-10 I NSTALLATION Open electrical enclosure. Connect the power cable to the main line connection. Check the short-to-ground with an ohm meter. Connect the ohm meter to each of the three terminalscrews and to the ...

Page 31 - Turn on main power source.; If the fluid level is low, follow the steps to add fluid. See

I NITIALLY S TARTING THE C HILLER UGH016/1200 Series 1 Portable Chillers, TIC Control I NSTALLATION 3-11 Turn on main power source. The control boots up and the screen displays the tempera-ture of the fluid going to the process. 1 WARNING: Initial startup Do not press any buttons after initially app...

Page 33 - Changing the Setpoint; PERATION

4-1 Series 1 Portable Chillers, TIC Control UGH016/0500 ● ● TIC Control Features . . . . . . . . .4-2 ● ● Before Starting . . . . . . . . . . . . . .4-3 ● ● Starting/Stopping the Chiller . . .4-4 ● ● Changing Settings . . . . . . . . . . .4-5 ● ● Changing the Setpoint Temperature . . . . . . . . . ....

Page 34 - TIC C; ONTROL

TIC C ONTROL F EATURES Series 1 Portable Chillers, TIC Control UGH016/0500 4-2 O PERATION Menu Access button Press to enter or changesetpoint, to exit the menu,and to index to the nextmenu. Raise button Increases values, hold forfast-step progression. Lower button Decreases values; holdfor fast-step...

Page 35 - Daily maintenance includes:

B EFORE S TARTING UGH016/0500 Series 1 Portable Chillers, TIC Control O PERATION 4-3 Before you start daily operation of the chiller, you need toperform scheduled preventative maintenance. Necessary main-tenance is describe in the Maintenance section of this UsersGuide. WARNING: Electrical hazard Be...

Page 36 - Press the Start Chiller button.; TARTING; The chiller remains on, but stopped. The display screen on

Plug in the power cord to restore power after any requiredmaintenance. The chiller control automatically performs its bootup routine.When bootup is complete, the screen displays the To Processtemperature. The chiller is ready to run. Press the Start Chiller button. Check the Pump and Compressor ligh...

Page 37 - The control allows you to change four settings:; Temperature Setpoint; The temperature you want the To Process liquid; Temperature Scale; Control Settings; HANGING THE; The current To Process temperature displays on the screen; Press Menu button once.; button for at

C HANGING S ETTINGS UGH016/0500 Series 1 Portable Chillers, TIC Control O PERATION 4-5 The control allows you to change four settings: ● Temperature Setpoint The temperature you want the To Process liquid ● Temperature Scale Choose to display temperature in degrees Fahrenheit orCelsius. ● Auto Tune ...

Page 39 - HANGING; The screen displays STBY and the new number.

UGH016/0500 Series 1 Portable Chillers, TIC Control O PERATION 4-7 C HANGING A UTO T UNE M ODE CONT ’ D Press the Menu button. SP displays, flashing alternately with the cur-rent setpoint temperature. Use the Up/Down arrows to change the setpoint temperature. Each time you pressan arrow, the display...

Page 40 - Press Menu button until INP shows; to accept the new temperature.; ETTING THE

The default low temperature limit for the To Process fluid isset at the factory at 40 °F. This temperature limit is the lowesttemperature for the chilled fluid leaving the Chiller. If youwant to cool fluid below 40 °F (4 °C) and down to 20 °F (-7 °C), you need to fill the chiller with the proper per...

Page 41 - Preventative Maintenance

5-1 Series 1 Portable Chillers, TIC Control UGH016/0500 ● ● Maintenance Features . . . . . . . .5-2 ● ● Warnings and Cautions . . . . . . .5-3 ● ● Preventative Maintenance Schedule . . . . . . . . . . . . . . . . .5-4 ● ● Checking the Refrigerant Charge . . . . . . . . . . . . . . . . . . .5-6 ● ● C...

Page 44 - There should not be any bubbles. See; REVENTATIVE

● ● Daily, or as often as needed ❒ ❒ Checking electrical connections Make sure electrical connections are properly seated.See Checking Electrical Connections , in the Maintenance section. ❒ ❒ Checking process fluid level in the pump tank Check the process fluid level in the water level gaugeon the b...

Page 45 - Monthly; Wipe all external surfaces to maintain performance.

P REVENTATIVE M AINTENANCE S CHEDULE UGH016/0500 Series 1 Portable Chillers, TIC Control M AINTENANCE 5-5 ● ● Monthly ❒ ❒ Inspecting cooling water treatment system If your chiller uses a cooling water treatment system,maintain proper chemical levels and follow the recom-mendations of your water trea...

Page 46 - Check refrigerant charge while the chiller is running:; Under full load conditions, the refrigerant should be; HECKING THE

Check refrigerant charge while the chiller is running: Check the refrigerant charge through the sightglass. Use a flashlight, if necessary, and check the liquid-linesight glass: ● Under full load conditions, the refrigerant should be clear (no bubbles). ● Under low load conditions, when the hot-gas ...

Page 47 - LEANING THE; CAUTION: Hot Surfaces

Water quality should be maintained at a pH of 7.4, but not lessthat 6.0 for proper heat exchanger life. To clean: Prepare a 5% solution of Phosphoric acid or Oxalic acid. Do not heat the acid solution. Shut the From Process valve. Disconnect the pump from the heat exchanger. Install a cap in the ope...

Page 48 - Use a flashlight to check between coil surfaces.; Clean the dirty coils with a soft brush.

C LEANING THE A IR - COOLED C ONDENSER Series 1 Portable Chillers, TIC Control UGH016/0500 5-8 M AINTENANCE WARNING: Electrical hazard Before performing any work on this item, dis-connect and lock out electrical power sources toprevent injury from unexpected energization orstartup. CAUTION: Hot Surf...

Page 49 - Be sure the main power is disconnected

C HECKING E LECTRICAL C ONNECTIONS UGH016/0500 Series 1 Portable Chillers, TIC Control M AINTENANCE 5-9 Be sure the main power is disconnected and the chiller is locked out. Always disconnect and lock-out the main power source before opening the unit forservicing. Open the electrical enclosure. Insp...

Page 50 - To manually fill the reservoir:; Disconnect and lockout power to the chiller.; HECKING

Check the fluid level in the reservoir. The meniscus in thesight glass on the back of the chiller should be in line with themark on the sight glass. To manually fill the reservoir: Disconnect and lockout power to the chiller. Locate the fill port on the back of the chiller. Refill the reservoir. Mon...

Page 51 - ROUBLESHOOTING

6-1 Series 1 Portable Chillers, TIC Control UGH016/0500 ● ● Before Beginning . . . . . . . . . . . .6-2 ● ● A Few Words of Caution . . . . . .6-2 ● ● Identifying the Cause of a Problem . . . . . . . . . . . . . .6-3 ● ● Answering an Alarm . . . . . . . . .6-4 ● ● Control Problems . . . . . . . . . ....

Page 52 - A F; Before you begin troubleshooting:

A F EW W ORDS OF C AUTION You can avoid most problems by following the recommendedinstallation, operation and maintenance procedures outlined inthis User Guide. If you have a problem, this section will helpyou determine the cause and tell you how to fix it. Before you begin troubleshooting: ❒ Find a...

Page 53 - Conditions you may see are:; electrical - a fuse is out, a switch has tripped; DENTIFYING; DAY

The Troubleshooting section covers problems directly relatedto the operation and maintenance of the portable chiller. Thissection does not provide solutions to problems that originatewith other equipment. Additional troubleshooting help can befound in manual supplied with the other equipment. Condit...

Page 55 - Symptom

UGH016/0500 Series 1 Portable Chillers, TIC Control T ROUBLESHOOTING 6-5 Symptom The control is not litand the chiller is notworking. Possible cause Power is not reaching thechiller. The correct power is notreaching the unit There is a problem withthe TIC control. There is a problem withthe control ...

Page 56 - There is a phase loss.; Solution; Check the fuses on the main

Symptom The control is lit andthere is no alarmcondition. The com-pressor hums, butdoes not run. Possible cause The input voltage isincorrect There is a phase loss. Solution Check the main supply volt-age. It must be within 10% ofthe nameplate rating. ❐ Check the fuses on the main power supply. ❐ Ch...

Page 57 - Answering an Alarm; Alarm; Water level in tank is low.; Fill tank to proper level. See

M ECHANICAL C ONDITIONS UGH016/0500 Series 1 Portable Chillers, TIC Control T ROUBLESHOOTING 6-7 Look here when the Alarm/Shutdown light on the controlpanel is lit. See Answering an Alarm , in the Troubleshooting section before going to these tables. Alarm Low Water TankLevel (pump andcompressor are...

Page 58 - The evaporator is fouled.; Fill the reservoir. See

M ECHANICAL C ONDITIONS Series 1 Portable Chillers, TIC Control UGH016/0500 6-8 T ROUBLESHOOTING Alarm Flow fault (pumpand compressor areoff) Possible cause The To Process and FromProcess valves are closed. The Process Fluid strain-er is clogged. Water level in reservoir islow. The evaporator is fou...

Page 59 - Possible cause; Overload set incorrectly.; Check supply voltage.

M ECHANICAL C ONDITIONS CONT ’ D UGH016/0500 Series 1 Portable Chillers, TIC Control T ROUBLESHOOTING 6-9 Alarm Pump Overload(pump and compres-sor are off) Possible cause Overload set incorrectly. Low supply voltage. Faulty contactor Faulty overload module. Solution Check table on wiring diagramfor ...

Page 61 - Cleaning

M ECHANICAL C ONDITIONS CONT ’ D UGH016/0500 Series 1 Portable Chillers, TIC Control T ROUBLESHOOTING 6-11 Alarm High DischargePressure (pump isrunning, compressoris off) Possible cause Clogged/dirty air-cooledcondenser. Blocked air flow to air-cooled condenser. Low condenser waterflow or water too ...

Page 62 - Faulty pressure switch.; See; ECHANICAL

Alarm High DischargePressure, cont’d Possible cause Compressor dischargevalve closed. Overcharged with refrig-erant. Faulty water regulatingvalve. Faulty pressure switch. Solution Open valve. See Checking the Refrigerant Charge in the Maintenance section. Repair or replace the valve. See Checking th...

Page 63 - No load on the Chiller.; Checking Pressure

M ECHANICAL C ONDITIONS CONT ’ D UGH016/0500 Series 1 Portable Chillers, TIC Control T ROUBLESHOOTING 6-13 Alarm Low SuctionPressure (pump isrunning and com-pressor is off) Possible cause No or low flow with afailed flow switch andRTD. Compressor suction valveis closed. No load on the Chiller. The E...

Page 64 - The compressor failed.; Contact Conair Service.

M ECHANICAL C ONDITIONS CONT ’ D Series 1 Portable Chillers, TIC Control UGH016/0500 6-14 T ROUBLESHOOTING Symptom Compressor fault. Possible cause Leads are backwards. The compressor failed. Solution Swap any two of the threemain power leads to the com-pressor. Contact Conair Service.

Page 65 - To check a flow switch:

C HECKING AND R EPLACING S WITCHES UGH016/0500 Series 1 Portable Chillers, TIC Control T ROUBLESHOOTING 6-15 Always refer to the wiringdiagrams that came withyour chiller to locate specificelectrical components. WARNING: Electrical hazard Before performing any work on this unit, discon-nect and lock...

Page 66 - To replace contactor for the pump or compressor:

R EPLACING THE C ONTACTOR Series 1 Portable Chillers, TIC Control UGH016/0500 6-16 T ROUBLESHOOTING To replace contactor for the pump or compressor: Disconnect and lockout power to the chiller. Open the electrical enclosure and locate the correct contactor. Refer to the wiring diagrams youreceived w...

Page 67 - HECKING AND; To Process connection.

UGH016/0500 Series 1 Portable Chillers, TIC Control T ROUBLESHOOTING 6-17 C HECKING AND R EPLACING THE RTD The Conair Portable Chiller uses a standard 100 ohm RTD tomonitor process temperature. Disconnect the RTD leads andmeasure the resistance through the RTD. It should read 95 -110 ohms. If it doe...

Page 69 - EPLACING; To replace the overload module:

UGH016/0500 Series 1 Portable Chillers, TIC Control T ROUBLESHOOTING 6-19 R EPLACING O VERLOAD M ODULES Always refer to the wiring dia-grams you received with yourchiller to locate specific elec-trical components. WARNING: Electrical hazard Before performing any work on this unit, discon-nect and lo...

Page 71 - EMOVING; Drain the water from the chiller.; Open the side of the chiller.; assembly to the pump housing.; Remove the pump assembly.

UGH016/0500 Series 1 Portable Chillers, TIC Control T ROUBLESHOOTING 6-21 R EMOVING P UMP C OMPONENTS The pump’s wet end (impeller, motor, and seal assembly) canbe removed for service. Disconnect and lockout power to the chiller. Open the drain/fill valve. Drain the water from the chiller. 1 2 Fill/...

Page 72 - WARNING: Coolant hazard

The pressure switch is a non-adjustable switch. To check thepressure switch: Locate the pressure switch. Use the wiring diagrams that came with your chiller forexact location. Location varies depending on size of unit. Check the connections. Make sure all connections to the switch are secure.Tighten...

Page 73 - Check the continuity within the switch; and make sure it corresponds to the following conditions:

UGH016/0500 Series 1 Portable Chillers, TIC Control T ROUBLESHOOTING 6-23 Check the continuity within the switch and make sure it corresponds to the following conditions: 4 Item High Pressure Switches (PS-2) Low Pressure Switches (PS-1) Description Cut out @ 300 PSIG on rise Cut out at 28 PSIG on fa...

Page 75 - PPENDIX; To contact Customer Service personnel, call:; RE

IMS0002/0296 S ERVICE I NFORMATION A PPENDIX A-1 Conair has made the largest investment in customer support inthe plastics industry. Our service experts are available to helpwith any problem you might have installing and operatingyour equipment. Your Conair sales representative also can helpanalyze ...

Page 76 - Inspect the equipment and perform alterations or

W ARRANTY I NFORMATION IMS0003/0796 E QUIPMENT G UARANTEE P ERFORMANCE W ARRANTY W ARRANTY L IMITATIONS Conair guarantees the machinery and equipment on thisorder, for a period as defined in the quotation from date ofshipment, against defects in material and workmanshipunder the normal use and servi...

Page 77 - Date; Discharge Pressure; Reading

UGH016/0500 Series 1 Portable Chillers, TIC Control A PPENDIX B-1 M AINTENANCE L OG Date Maintenance Item Compressor Amps,100% loaded Discharge Pressure Suction pressure Evaporator water outtemperature Process Water Pressure,In/Out Condenser WaterTemperature, In/Out Condenser WaterPressure, In/Out C...

Page 80 - RESSURE

Series 1 Portable Chillers, TIC Control UGH016/0500 A PPENDIX C-2 Condenser and Piping Pressure Drops P RESSURE T ABLES 0 10 10 20 20 30 30 40 40 50 50 60 60 70 70 80 80 0 5 10 10 15 20 25 25 30 35 35 40 45 50 50 55 Pressure Dr op, PSID Flow Rate, GPM W1-10 W1-5 W1-2 W1-1.5 W1-3 W1-4 W1-7.5 W1-15

Page 83 - ARTS

P/D-1 UGH016/0500 Series 1 Portable Chillers, TIC Control ● ● Spare Parts Lists . . . . . . . . . .P/D-2 P ARTS & D IAGRAMS

Page 84 - Part

R ECOMMENDED S PARE P ARTS Series 1 Portable Chillers, TIC Control UGH016/0500 P/D-2 S PARE P ARTS Part Number Description Athena 1/32 DIN Temperature Controller120VAC LOGO! Long120VAC 4” Alarm Bell20VAC White Strobe22 mm Red extended pushbutton operator 22 mm Green flush pushbutton operator120VAC G...

Page 86 - Discharge pressure switch, cut out at 300 PSIG on

R ECOMMENDED S PARE P ARTS Series 1 Portable Chillers, TIC Control UGH016/0500 P/D-4 S PARE P ARTS Part Number 209730032663610126629901 26638902 26638901 26638903 2663890 209668023310210512920580201 2920581001 2920581301 2920580202 2920581302 2920940902292094130229209418022921310329213104 Descriptio...