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Conair microKool MPA, User Manual

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Conair microKool MPA User Manual Download Page 57

6-1

UGH009/0999

microKool Portable Chillers

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Before beginning  . . . . . . . . . . . .6-2

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A few words of caution  . . . . . . .6-2

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How to identify the cause 

of a problem  . . . . . . . . . . . . . . .6-3

D

IAGNOSTICS

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Shut down alarms  . . . . . . . . . . .6-4

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Warning alarms  . . . . . . . . . . . .6-10

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System alarms  . . . . . . . . . . . . .6-11

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Chiller will not power up  . . . . .6-12

R

EPAIR

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Checking and replacing fuses .6-13

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Resetting overloads . . . . . . . . .6-14

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Replacing the pump overload  .6-14

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Replacing the motherboard  . . .6-15

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Replacing the compressor

contactor  . . . . . . . . . . . . . . . .6-16

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Checking the unloader valve  . .6-17

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Replacing the freezestat  . . . . .6-18

T

ROUBLESHOOTING

Summary of Contents for microKool MPA

Page 1: ......

Page 2: ...er UGH004 0999 Serial number s Model number s DISCLAIMER The Conair Group Inc shall not be liable for errors contained in this User Guide or for incidental consequential dam ages in connection with th...

Page 3: ...upply lines 3 4 Connecting the main power 3 5 Testing the installation 3 6 Entering setpoint deviation parameters 3 7 Initial setup 3 8 Changing temperature units 3 9 Enabling and disabling passcode p...

Page 4: ...a Problem 6 3 DIAGNOSTICS Shut Down Alarms 6 4 Warning Alarms 6 10 System Alarms 6 11 Chiller Will Not Power Up 6 12 REPAIR Checking and Replacing Fuses 6 13 Resetting and Replacing Overloads 6 14 Re...

Page 5: ...1 1 UGH004 0999 microKool Portable Chillers 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 INTRODUCTION...

Page 6: ...ns 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 diamond in...

Page 7: ...le power is on WARNING Improper installation operation or servicing may result in equipment damage or personal injury This equipment should be installed adjusted and serviced by qualified technical pe...

Page 8: ......

Page 9: ...is the microKool chiller 2 2 Typical applications 2 2 How it works Water cooled models 2 3 How it works Air cooled models 2 4 Features 2 5 Specifications Water cooled 2 6 Specifications Air cooled 2...

Page 10: ...indicator lights dis play the status of the chiller components The enhanced PC 2 control offers the same features as the standard control plus autostart capabilities which enables the chiller to start...

Page 11: ...s An in line sight glass gives a visual indication of proper refrigerant charge and any dangerous moisture pre sent in the system The refrigerant passes through a thermal expansion valve where it expa...

Page 12: ...s through a filter dryer which protects the system from moisture or other contami nants An in line sight glass gives a visual indication of proper refrigerant charge and any dangerous moisture pre sen...

Page 13: ...ith cooling loads as low as 25 of rated chiller capacities Corrosion Free Evaporators On models through 7 5 Hp chilled water flows through heavy gauge tube in tube evaporators The water comes in conta...

Page 14: ...1080 490 1080 490 Utility requirements Water connections NPT female inches 1 1 1 1 5 1 5 1 5 1 5 Process and condenser water inches 1 1 1 1 5 1 5 1 5 1 5 Voltages running and full load amps run full r...

Page 15: ...1200 544 1200 544 1400 635 1600 726 Installed weight 610 277 830 376 830 376 1030 467 1030 467 1230 558 1430 649 Utility Requirements Water connections NPT female inches 1 1 1 1 5 1 5 1 5 1 5 Process...

Page 16: ...20 30 40 50 60 20 0 40 60 80 100 40 30 20 10 0 10 20 30 40 50 60 70 80 20 0 40 60 80 100 Freeze Protection Requirements by Unit Set Temperature Freezing Points of Aqueous Ethylene Glycol Solutions Et...

Page 17: ...ting the main power 3 5 Testing the installation 3 6 Entering setpoint deviation parameters 3 7 Initial setup 3 8 Changing temperature units 3 9 Enabling and disabling passcode protection 3 10 Selecti...

Page 18: ...aced there for shipping Carefully inspect all components to make sure no damage occurred during shipping and that you have all the necessary hardware If damage is found notify the freight company imme...

Page 19: ...ated environment The room temperature should not exceed 110 F 43 C with 95 non condensing humidity and should not fall below 55 F 12 C Minimum clearance for safe operation and mainte nance Nothing sho...

Page 20: ...ns are labeled on the chiller Start by hand until the threads engage then use a pipe wrench to tighten the connection only enough to prevent leaks Do not over tighten CONNECTING PROCESS AND WATER SUPP...

Page 21: ...nect the ground wire to the copper grounding mount If you have installed a disconnect device follow the manufacturer s wiring instructions 1 2 3 4 5 CONNECTING THE MAIN POWER SUPPLY WARNING Electrical...

Page 22: ...erminal block Return to Step 2 and check rotation again Replace the access panel Press the RUN key to start the unit If everything is working correctly The RUN STOP light turns green The pump begins o...

Page 23: ...emperature deviation settings Press the Setpoint Select button to select the deviation parameter you want to change Use the and setpoint buttons to enter the deviation temperature The setting is store...

Page 24: ...Dip switch Configuration No OFF ON 1 Display units in F Display units C 2 Auto Tune disabled Auto Tune enabled 3 Passcode protect Password reset modify 4 Auto Start disabled Auto Start enabled 5 Cont...

Page 25: ...1 on the control circuit board Disconnect and lock out main power to the chiller Open the electrical enclosure Change Dip Switch 1 to OFF for F ON for C Close the electrical enclosure and restore mai...

Page 26: ...sure Set dip switch 3 to ON and switches 5 and 6 to OFF Close the electrical enclosure and restore power to the unit Press any button when the control dis plays Pas rSt Passcode Reset The control will...

Page 27: ...ch 3 to OFF Close the electrical enclosure and restore power to the unit A passcode now is required to change system parameters INSTALLATION 3 11 7 8 1 2 3 4 5 6 7 8 9 10 11 ENABLING AND DISABLING PAS...

Page 28: ...Set dip switch 5 to the ON position Close the electrical enclosure and restore power to the unit Press any button when the control displays Cnt Pt The controller will display Sel CnP and flashes the L...

Page 29: ...the unit IMPORTANT If RUN is not pressed the new control point source will not be saved Turn off power to the unit Disconnect and lock out the main power supply Open the electrical enclosure Set dip s...

Page 30: ...your switching or timing device Insert the two power leads from the device through the conduit into the electrical enclosure Connect the 110VAC device contact wires to the Auto Start terminals Make s...

Page 31: ...icate that the Chiller can start at any time The chiller will start whenev er the remote switching or timing device sends a signal to start processing The Auto Start indicator light is on whenever the...

Page 32: ...PaS use the setpoint adjustment but tons to enter the passcode Enter the node address Press the Setpoint Select button to choose Address Then press the setpoint or arrow until the address you want ap...

Page 33: ...ler PC 1 control features 4 2 PC 2 control features 4 3 Positioning the control panel 4 4 Entering a passcode 4 5 Starting the chiller 4 6 Stopping the chiller 4 7 Using the PC 2 pumpdown feature 4 9...

Page 34: ...ture high and low temperature deviation alarms the SPI baud rate and the SPI address Setpoint and Actual value display windows also display some alarm codes and setup instructions Run Stop Press the R...

Page 35: ...int for this temperature is selectable as the temperature at the supply outlet return inlet or the average of the two temperatures The lights indicate whether the temperature is in degrees Fahrenheit...

Page 36: ...trol panel is flush with the unit To detach the PC 2 control panel The PC 2 control panel may be removed and mounted up to 50 feet from the unit Do not stretch the cable The cable is available in vari...

Page 37: ...S to indi cate a passcode is needed Press the Select button until the correct passcode appears in the display Press again to enter the passcode If the passcode is correct the control displays ACC PAS...

Page 38: ...passcode if necessary Hold the Setpoint Select button for 5 seconds When the control displays 1 PaS use the setpoint adjustment buttons to enter the passcode Press the Setpoint Select button again Ent...

Page 39: ...nnect all process and water connections In ship ment or storage the chiller can withstand an environment between 40 F 40 C and 150 F 65 C with 95 rela tive humidity non condensing The microKool must b...

Page 40: ...cess value is in ambient temperature This allows the software to obtain good approximations of process parameters which are crit ical for performing an accurate tune If this requirement is not met the...

Page 41: ...DESCRIPTION Insufficient setpoint process deviation If the absolute value of setpoint process value is less than 25 F The Auto Tune can not be started until the temperature difference is at least 25 F...

Page 42: ......

Page 43: ...ors 5 4 Cleaning condensers 5 4 Filling the tank 5 5 Checking refrigerant charge 5 6 Performing system tests 5 7 Key Display Test 5 8 Input Test 5 9 Output Test 5 10 Disabling or enabling output monit...

Page 44: ...obstructions on the unit especially around air intake areas Keep the floor around the unit dry If you notice a decrease in efficiency over time check all heat transfer surfaces of the evaporator and c...

Page 45: ...e performance especially in the water cooled chiller s condenser Clean all water cooled condenser surfaces The refrigerant side does not foul because the refrigerant acts as a solvent and operates in...

Page 46: ...circuit For water cooled condensers You should consult a water treatment specialist for recommendations on the best chemicals to use to remove contami nants from the condenser Thoroughly flush chemica...

Page 47: ...er or glycol mixtures make sure you are adding the correct fluid for your application REFILLING THE TANK UGH004 0999 microKool Portable Chillers MAINTENANCE 5 5 1 2 IMPORTANT Do not use deionized wate...

Page 48: ...d between the evaporator and the condenser Use a flash light to look at the liquid line sight glass Under full load conditions the sight glass should be clear Under low load conditions when the hot ga...

Page 49: ...trol displays tSt The Test Mode LED lights Press any button to display the first test menu Test mode provides the following menus Key Display Test Input Test Output Test Calibration Total Operating Ho...

Page 50: ...u until the controller displays dSP Press any key to clear all displays Repeatedly press any key to test displays With each key press a new segment of all six 8 segment LEDs and a select group of LED...

Page 51: ...to index to each test menu until the controller displays InP Repeatedly press and release any key to test With each key press and release the left display will indi cate the number of the input being...

Page 52: ...enu until the controller displays oUt Repeatedly press and release any key to test With each key press and release the left display will indi cate the number of the output being tested oS1 OM1 oS2 OM2...

Page 53: ...etpoint key for 3 seconds to index to each test menu until the controller indicates oS1 in the actual display and the status of the selected output in the Select display Press the Setpoint or key to c...

Page 54: ...ds to index to each test menu until the controller indicates SC L in the Actual display Release the Setpoint key You are now in calibration mode Each press and release of this key will exit the curren...

Page 55: ...e end of a calibration tells the controller to perform the next calibra tion Exit Calibration Mode Press and hold the Select key for 3 seconds to exit the Calibration Mode You can now proceed to the n...

Page 56: ...icates Log The Setpoint display indicates the total number of operat ing hours in 100 hour units Exit the Operating Hours Log Press and hold the Select key for 3 seconds to exit and index to the next...

Page 57: ...ICS Shut down alarms 6 4 Warning alarms 6 10 System alarms 6 11 Chiller will not power up 6 12 REPAIR Checking and replacing fuses 6 13 Resetting overloads 6 14 Replacing the pump overload 6 14 Replac...

Page 58: ...control panel These indicators will help you discover the cause of the problem more quickly The chiller is equipped with many safety devices Do not remove or defeat them Improper corrective action ca...

Page 59: ...the microprocessor control When the chiller control detects a problem the red Alarm light is activated and the RUN STOP light changes from green to flashing red When an Alarm condition occurs Press to...

Page 60: ...pump sizing for the application Decrease the water flow from the process Disconnect the power and open the electrical enclosure Verify that the overload is set to trip at the proper amperage which sho...

Page 61: ...ocouple loose Has the thermocouple failed Is the thermocouple loose Has the thermocouple failed Solution Check phase continuity through the compressor con tactor If the contactor has failed replace it...

Page 62: ...ocation Has the motherboard output channel at the designated fuse failed Solution Check pump rotation against the arrow stamped on the pump If the pump is rotating in the wrong direction discon nect a...

Page 63: ...h compressor sizes 15 Hp and above Possible cause Is the correct voltage supplied to the motor on the compressor Is the overload faulty or set incorrectly Is the compressor faulty Oil level in the com...

Page 64: ...en Verify that the suction valve at the compressor is open Verify that the expansion valve is working properly Check for closed valves and obstructions contaminants or dirt that may have blocked or re...

Page 65: ...ion if a tower supplies the water Contact a certified refrigerant technician for servicing Check the fluid level by look ing at the tank level sight glass at the rear of the chiller Add fluid if neces...

Page 66: ...ss setpoint Increase the high deviation limit setting The recommend ed setting is 2 F to 10 F above the process setpoint Check for plugged pipes and closed valves Clear any obstructions and open valve...

Page 67: ...n Make sure all connections on the motherboard are solid Operate unit in a noise free environment If error persists contact Conair service Make sure the CPU and PROM chips are seated correctly in the...

Page 68: ...ower supply and any customer installed electrical discon nect or emergency stop devices are in the ON posi tion Verify correct electrical con nections between the unit and the control and between the...

Page 69: ...e sensing device for the fuse location Check all wiring referencing the fusing location for loose connections damage or improper grounding Verify that the correct device is being used for this fuse lo...

Page 70: ...the starter Reverse these steps to install the new overload module Set the module reset mode to M for manual Set the proper FLA trip point Do not exceed the FLA for the pump motor microKool Portable...

Page 71: ...6 CONFIGURATION DIP SWITCH OFF ON 4 3 2 1 4 3 2 1 UNLDR 1 VENT 2 SOL UNLDR 1 VENT 2 SOL UNLDR 2 COOL 1 SOL UNLDR 2 COOL 1 SOL F5 F4 F2 PUMP PUMP PUMP OL PUMP OL 6 5 4 3 2 1 4 3 2 1 6 5 4 3 2 1 F3 4 3...

Page 72: ...the compressor con tactor contactor Label the wires to ensure you can connect them correctly to the new contactor Remove and discard the old contactor Reverse this procedure to install the new con tac...

Page 73: ...Clear any alarms and restart the chiller Watch for the following The unloader valve light should turn on for 2 seconds when the compressor starts You should hear the sole noid activate when the unload...

Page 74: ...cal enclosure and locate the freezestat unit Disconnect freezestat unit wires from their ter minals Mark the wires so that you can easily reconnect the new unit to the appropriate terminals Loosen the...

Page 75: ...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 76: ...ill exercise 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...

Page 77: ...e chillers Device ID hex 21 Commands Select Poll Echo 0x21 0x21 Select stores 4 bytes of information at the chiller Poll retrieves it 0x21 0x20 Setpoint Process Temperature 0x21 0x21 Sets and retrieve...

Page 78: ...Test Mode Phase error NOTES The SPI I O list defines the Processing bit as being cleared if the unit is not processing otherwise it is SET Elsewhere on the chart If a bit is not shown to be SET it is...

Page 79: ...water level SET SET Test Mode Phase error SET SET SET NOTES The SPI I O list defines the Processing bit as being cleared if the unit is not processing otherwise it is SET Elsewhere on the chart If a b...

Page 80: ...SET SET Compressor overload SET SET Freeze Stat Low water level SET SET Test Mode Phase error NOTES The SPI I O list defines the Processing bit as being cleared if the unit is not processing otherwise...

Page 81: ...PD 1 UGH004 0999 microKool Portable Chillers PC 1 Wiring Diagram PD 2 PC 1 Circuit Board PD 3 PC 2 Wiring Diagram PD 4 PC 2 Circuit Board PD 5 Parts Lists PD 6 PARTS DIAGRAMS...

Page 82: ...PC 1 WIRING DIAGRAM UGH004 0999 PD 2...

Page 83: ...TR GND GND TR TR 120 Ohm 1 2 3 4 5 6 7 8 4 3 2 1 6 5 4 3 2 1 4 3 2 1 1 2 3 4 PC 1 CIRCUIT BOARD WARNING IT IS VERY IMPORTANT THAT SWITCHES 7 AND 8 BE SET TO THE PROPER UNIT TYPE BEFORE OPERATING THIS...

Page 84: ...PC 2 WIRING DIAGRAM UGH004 0999 PD 4...

Page 85: ...3 2 1 1 2 3 4 PC 2 CIRCUIT BOARD WARNING IT IS VERY IMPORTANT THAT SWITCHES 7 AND 8 BE SET TO THE PROPER UNIT TYPE BEFORE OPERATING THIS UNIT CHILLER 7 ON 8 OFF 1 2 0 O h m J U M P E R D B 9 5 9 D B...

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