SP Scientific RS Series Operator'S Manual Download Page 1

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ECIRCULATING

HILLER

PERATOR

’

ANUAL

RS44XX2MCT

HILLER

ERIES

HILLER

Summary of Contents for RS Series

Page 1: ...RECIRCULATING CHILLER OPERATOR S MANUAL RS44XX2MCT CHILLER RS SERIES CHILLER ...

Page 2: ......

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: ...f 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 employees or a...

Page 6: ...iv Rev 004 04 12 SP Scientific 2012 ...

Page 7: ...hysical Location 4 Ambient Conditions 4 Electrical Requirements 5 Selecting a Process Fluid 6 Properties of a Process Fluid 7 Connect to the Process 8 Prime the Fluid Loop 9 Operation 11 System Preparation 11 Start Up 11 Control 12 Shut Down 12 User Menu 13 Overview 13 Buttons 13 Operating Mode 14 Proportional Control Menu 15 SPAN Menu 16 Miscellaneous Menu 17 Communications Menu 18 PID Tuning 19 ...

Page 8: ...use Replacement 24 Cleaning 25 Draining Fluid 26 RS 232 Communications 27 Overview 27 Hardware 27 Communications 29 Communication Data 29 Data Format 29 Received Data 30 Transmitted Data 32 Transmitted Data Format 33 Acknowledge 33 Error 33 Value 33 Terminator 34 Commands and Codes 34 Command Set 34 Alarm Codes 41 RS 232 Error Codes 42 Sample Program 45 Program 45 Appendix A Troubleshooting 47 ...

Page 9: ...re controlled fluid over a wide range All SP Scientific chillers feature innovative design high quality construction and highly reliable components This chiller will dependably serve your cooling needs for years to come Key Features Small Footprint Digital RS 232 Control 0 1 C Stability Wide Temperature Range Mechanical Refrigeration Air Cooled ...

Page 10: ...Introduction RS44XX2MCT Chiller 2 Rev 004 04 12 SP Scientific 2012 ...

Page 11: ...scovered contact the 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 clai...

Page 12: ...N AND AREA WHERE EXCESSIVE HEAT MOISTURE OR CORROSIVE MATERIALS ARE PRESENT Ambient Conditions This unit is designed for operation in a normal 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 d...

Page 13: ...al tag on the rear of the machine The electric service wiring must be of a large enough wire gauge that the voltage is maintained to the receptacle even when a full load is applied to the receptacle Additionally the receptacle voltage should be measured while that receptacle is under load Ensure the proper amperage circuit breaker is installed in the line and located near the equipment Plug in the...

Page 14: ... Oil for 60 C to 100 C If you require a completely non flammable fluid SP Scientific suggests Galden fluids made by the Ausimont Company 800 323 AUSI Galden fluids are non flammable inert and non toxic There are other fluids available but to avoid potential application problems and to speed troubleshooting it is suggested that one of the fluids mentioned above be used DO NOT USE AUTOMOTIVE ANTI FR...

Page 15: ... mistaken for boiling of the fluid Water Solubility Process fluids are water soluble After long periods of operation at low temperatures water from the air will condense on and mix with the fluid This decreases the performance of the system To remove excess water warm the fluid to room temperature and pump the fluid through a molecular sieve or desiccant material Alternately simply run the system ...

Page 16: ...fluid To tie these lines into your process you will require 1 4 Fittings for 1 4 male pipe thread on the fluid I O ports Pipe Insulation Closed cell pipe insulation will work for most applications which 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 ...

Page 17: ... SUITABLE GLOVES SAFETY GLASSES AND PROTECTIVE CLOTHING WEAR SAFETY GLASSES Add process fluid to reservoir until it is 1 2 5cm from the top and replace the 2 lid Press the I O button 3 When the reservoir drops to 1 3 full press the I O button to stop the pump 4 Remove the reservoir lid 5 Add fluid to reservoir until it is again 1 2 5cm from the top and replace the 6 lid Restart the pump by pressin...

Page 18: ...Installation and Startup RS44XX2MCT Chiller 10 Rev 004 04 12 SP Scientific 2012 ...

Page 19: ... 2 Display will be blank and the amber Power light will be illuminated 3 Start Up Press the I O button 1 Display flashes SP setpoint then the current setpoint temperature the 2 setpoint is the fluid temperature that the unit will maintain Adjust the Setpoint using the keys 3 The value for setpoint will be accepted after 4 seconds of inactivity 4 ...

Page 20: ... the expansion 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 The setpoint is automatically accepted after 4 seconds 3 Shut Down Press the I O button to put the unit back in Idle 1 The refrigeration will shut down and ...

Page 21: ...s Proportional Control parameters and several Communications options can all be adjusted from the User Menus The layout of the menus and 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 following pages show how to use these buttons to move around the menus and manipulate the va...

Page 22: ...Proportional 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...

Page 23: ...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 as it...

Page 24: ... without 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 ...

Page 25: ...ut setpoint 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...

Page 26: ...Rate 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 27: ...n Program 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 con...

Page 28: ...the controller using the instructions outlined in PID tuning CCt To determine the Cool Cycle Time CCt run the unit at the temperature at which you wish to maintain control 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 th...

Page 29: ...er Description The level of the process fluid in the reservoir has dropped below acceptable limits The Low Fluid report is designed to protect the pump system and process equipment if the fluid level drops Decreasing levels could result from normal evaporation or could be the result of a leak in the chiller the process equipment or the lines between In addition certain process fluids have extremel...

Page 30: ...e 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 SP Scientific Service if the condition persists Low Fluid Temperature How Reported The display will flash...

Page 31: ...anty 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 The necessary equipment should be available to allow the user to comply with OSHA 29 CFR 1910 147 Control of Hazardous Ener...

Page 32: ...Maintenance RS44XX2MCT Chiller 24 Rev 004 04 12 SP Scientific 2012 Fuse Replacement Replace fuses only with the type and rating specified by the orange utilities label Fuse Location Utilities Label ...

Page 33: ...ronment Disconnect electric utilities 1 Check switch for proper operation 2 Vacuum dust from the refrigeration condenser as well as all screens and 3 openings Remove cabinet panels 4 Blow compressed air systematically from the top to bottom Let air settle for 5 several minutes and repeat Check for areas that have frosted during operation and insulate as required 6 Connect electric utilities 7 ...

Page 34: ...ns to replace the fluid to change the type of fluid used during maintenance during repairs etc Place a large low pan underneath the black drain hose 1 With a screw driver loosen the clamps on the end of the drain hose 2 Remove the plug 3 Once the unit is completely drained replace the plug 4 Reposition and tighten the hose clamp 5 Drain Hose ...

Page 35: ...tempts to communicate be unsuccessful that this program be tried It is as straightforward 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 wi...

Page 36: ...ver cable The custom wired cable will be a direct connection between your computer terminal and the Multi Cool However the null modem adapter is inserted between the female jack on the Multi Cool and a standard connecting RS 232 cable Female RS 232 Port on Multi Cool Male RS 232 Port on Computer Custom Wired Connector Cable Female RS 232 Port on Multi Cool Male RS 232 Port on Computer Standard Con...

Page 37: ...ty and stop bits are made to the microcontroller via the control panel of the target application system Communication Data All programmable selectable or switchable functions of the target system are accessible via the RS 232 with the exception of the RS 232 configuration itself which may not be programmed from the host All data programmed values status and system errors are accessible by the host...

Page 38: ...128 characters A listing and description of the available CMD statements appears in a later section Data commands that are grouped on a line must be separated by a single Space ASCII 032 decimal 20 hex The Delete Rubout character ASCII 127 decimal 7F hex will NOT be recognized Unrecognized characters will result in an error acknowledge ANY error in transmission reception of a line will assume corr...

Page 39: ...field may not exceed eight an error will result accordingly Leading zeroes or trailing zeroes behind a decimal point may be added without effect up to the character limit Examples SP 20 Adjust Setpoint to 20 degrees SP 20 Adjust Setpoint to 20 degrees SP 020 00 Adjust Setpoint to 20 degrees SP 60 3 Adjust Setpoint to 60 3 degrees CPB 3 6 Adjust Cooling Proportioning Band to 3 6 degrees Controllabl...

Page 40: ...ameter and its value will 3 be returned to the host If multiple value status queries are transmitted in a single statement the multiple replies will be transmitted on multiple lines i e separated by carriage returns Terminator Character All messages will be terminated by an exclamation 4 point ASCII 033 decimal 21 hex This character is appended to a single line message including OK or to the end o...

Page 41: ... due 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 d...

Page 42: ...to 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 ...

Page 43: ...rees 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 rev...

Page 44: ...d 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 A...

Page 45: ... 0 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 ...

Page 46: ...rative 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 PUMPS...

Page 47: ...and 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 h...

Page 48: ...t 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 se...

Page 49: ...ure 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 C...

Page 50: ...UART 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 receiv...

Page 51: ...8 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 ...

Page 52: ...ready 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 contr...

Page 53: ...o 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 m...

Page 54: ...RS 232 Communications RS44XX2MCT Chiller 46 Rev 004 04 12 SP Scientific 2012 ...

Page 55: ...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 56: ...ing 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 volt...

Page 57: ...ration in an ambient environment of 72 F 22 C Temperatures over 80 F 27 C may cause the compressor to overheat Fan not working Check the fan for rotation If the fan is not rotating check AC supply to the fan For blockage Excessive dirt dust Condenser blocked The finned condenser requires adequate airflow to provide cooling Make sure that the finned surface is 6 away from the wall and not clogged w...

Page 58: ...Appendix A Troubleshooting RS44XX2MCT Chiller 50 Rev 004 04 12 SP Scientific 2012 ...

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Page 60: ...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 ...

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