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Summary of Contents for PolyScience DuraChill 58 Series
- Page 1 User Guide DuraChill Air- and Water-Cooled 1.5 HP Chillers 110-392 27 June 2016...
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Page 3: Table Of Contents
Table of Contents Introduction ................................3 General Safety Information .............................3 Safety Recommendations ............................3 Regulatory and Compliance Testing ........................5 Contents .................................5 Controls and Components ............................6 Control Panel ...............................6 Front ..................................6 Rear -- 230V, 240V, and 208-230V Units ......................7 Rear -- 380V and 460V Units ..........................7 Quick Start .................................8 Installation and Startup ............................9 Site Requirements ..............................9... - Page 4 Fluid Level ................................ 24 Cleaning ................................24 Temperature Calibration ............................25 Internal Calibration Offset (c1) ..........................25 External Calibration Offset (c2) ..........................25 Flow Rate Calibration (Fc) ............................ 26 Fuse Bits (Fb) ................................. 26 Troubleshooting ..............................27 Diagnostic Mode ..............................28 Technical Information ............................
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Page 5: Introduction
Introduction DuraChill Chillers provide cooling power for demanding applications and serve as an economical alternative to tap water cooling systems. All models feature a microprocessor-based controller, digital Temperature Display (°C or °F), one-touch set point display, and digital Pressure/Flow Rate Display (PSI, kPa, GPM, LPM) with push-Button selection. - Page 6 WARNING: Always operate the unit within the stated temperature and pressure design specifications. WARNING: All warning labels should be carefully observed. Never remove or obstruct a warning label. WARNING: Units which use cooling fluid must be properly filled before use and properly drained before moving or service.
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Page 7: Regulatory And Compliance Testing
Regulatory and Compliance Testing Canada USA (60Hz) units CAN/CSA C22.2 No. 61010-1-12 – Safety Requirements for Electrical Equipment for Measurement, Control and Laboratory Use, Part I: General Requirements. CAN/CSA C22.2 No. 61010-2-010-04 (R2014) – Safety Requirements for Electrical Equipment for Measurement, Control and Laboratory Use –... -
Page 8: Controls And Components
Controls and Components Control Panel Unit / Menu Select Button Temperature Units Pressure / Flow Rate Display Select / Set Knob Pressure / Flow Rate Units Power Button Temperature Display Reservoir Cap Front Bypass Valve Access Panel Control Panel Ambient / External Temperature Tracking Probe Connection (optional) -
Page 9: Rear - 230V, 240V, And 208-230V Units
Rear – 230V, 240V, and 208-230V Units Communications Port (optional) Power Switch / Circuit Breaker RS-232 Port (optional) Remote Temperature Reservoir Vent Probe Port (optional) (Vent Assembly required on 5XXX models) Fluid Inlet (from process) Fluid Outlet (to process) Over-Temperature Protection Adjust (5XXX models only) Over-Temperature Protection... -
Page 10: Quick Start
Quick Start See Installation & Startup for additional information. All units: Connect process lines Water-cooled units: A. Connect process lines B. Connect facility water lines C. Turn facility water ON Fill reservoir with coolant Connect electrical power to Mains Turn Power Switch / Circuit Breaker ON Turn Controller ON Add coolant to reservoir as... -
Page 11: Installation And Startup
Installation and Startup Site Requirements Ambient Temperature and Relative Humidity The Chiller is designed for indoor installation in ambient temperatures between 16° and 35°C (60° and 95°F); relative humidity should not exceed 80% (non-condensing). Location Install the Chiller on a strong, level surface as close to possible to the process requiring cooling. It should not be installed closer than 4 feet (1.4 meters) to a heat-generating source. -
Page 12: External Piping
External Piping Process Fluid Inlet Reservoir Vent (shown with Vent Assembly for Process Fluid Outlet 5XXX models)) Facility Water Inlet Facility Water Outlet Reservoir Drain General Considerations It is the user’s responsibility to ensure that the tubing and fittings connected to the Chiller are compatible with the fluid, temperature, and pressure being used. -
Page 13: Process Fluid Connections
Process Fluid Connections The Chiller has two internally threaded fittings on the rear of the instrument housing for the process water connections. Two sets of adapters are supplied with the unit for connecting these fittings to the process piping. The direction of the flow through the system can be controlled by the way the connections are made. Fluid is drawn into the Chiller through the “Inlet”... -
Page 14: Process Coolant
Process Coolant Suitable Fluids WARNING: For units that use cooling fluids. Use only fluids that comply with safety, health, and equipment compatibility requirements. Read the safety data sheet for the fluid being used carefully before use. CAUTION: DO NOT USE Caustic, corrosive, or flammable liquids Automotive anti-freeze* Hard tap water*... -
Page 15: Electrical Power
Electrical Power WARNING: Do not plug unit into the electrical outlet until it is ready for startup. Always connect the power cord on this unit to a grounded power outlet. Make certain that the outlet is the same voltage and frequency as your unit (see identification label). Never operate the unit with a damaged power cord. -
Page 16: Startup
Startup Facility Water Flow (water-cooled units only) 1. Open the valves to the facility water supply and return. 2. Check for leaks. Filling the Reservoir 1. Remove the reservoir cap located on the top of the Chiller and, using a funnel, add fluid until it is approximately 2 inches (5.1 cm) below top of reservoir. -
Page 17: Normal Operation
Normal Operation NOTE: The Chiller incorporates a special "lockout" feature that can be enabled to prevent unauthorized or accidental set point and other operational changes. This feature is described in detail under "Enabling and Disabling the Local Lockout." It should not be enabled until all operational parameters have been set. Selecting the Temperature Unit (°C or °F) The LEDs adjacent to the Temperature Display indicate the unit (°C or °F) used for Temperature Displays. -
Page 18: Displaying And Adjusting The Ambient Tracking Offset
Displaying and Adjusting the Ambient Tracking Offset NOTE: Ambient tracking is an optional function that may or may not be available on your Chiller. It permits you to control fluid temperature based on room or machine temperature plus or minus a user-adjustable offset temperature. -
Page 19: Setting Operational Parameters / Limits
Setting Operational Parameters / Limits Various operational parameters are user-adjustable. They are accessed by pressing and holding the Units/Menu Button until HL appears on the Pressure/Flow Rate Display. Pressing and releasing the Units/Menu Button once HL appears allows you to scroll through the various parameters; rotating the Select/Set Knob allows you to change the displayed setting. - Page 20 Menu Item Description Choices / Ranges Default Setting Maximum Fluid Pressure — Maximum allowable fluid pressure; settable in either PSI or kPa. Should the fluid pressure rise above the maximum fluid pressure value, the audio and visual alarms will activate and the compressor, heater, fan, and pump will turn OFF.
- Page 21 Menu Item Description Choices / Ranges Default Setting Current Control (optional) — Allows setting of the set point temperature via a 4-20 mA analog signal. yES — Enables current control. Yes or No NO — Disables current control. 24 (2400), 48 (4800), Communications Baud Rate —...
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Page 22: Display, Alarm And Error Messages
Display, Alarm and Error Messages When certain conditions are detected, a message code flashes on the display and the local audio alarm sounds. Depending on the nature of the condition, power to various systems components is removed. When the condition is rectified, push the front panel Power Button or turn the circuit breaker OFF then ON to clear the fault or error. - Page 23 If a fault should occur, the left display will show Ft, and the right display will show one of the fault codes shown below. Fault Code Description Action Required Alarm — Process fluid temperature is below the low temperature limit value for more than 25 seconds. Compressor, heater, and fan Low limit temperature are turned OFF;...
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Page 24: Adjusting The High Pressure Bypass Setting
Adjusting the High Pressure Bypass Setting Chillers with a positive displacement or turbine pump incorporate an automatic safety to maintain outlet pressure below a valve-regulated pressure. This valve is adjustable and is located inside the Chiller housing. WARNING: Service should only be performed by fully qualified personnel. Extreme caution is required as hazards are present when servicing this equipment. -
Page 25: Over-Temperature Protection
Over-Temperature Protection 6XXX Chillers — The OTP for 6XXX model Chillers is fixed at a cutout temperature of 60°C. The OTP will auto- reset once the fluid temperature drops below the cutout temperature. 5XXX Chillers — The OTP for 5XXX model Chillers with the heater option is adjustable and disconnects power to the heater at a factory-set temperature of 95°C. -
Page 26: Routine Maintenance
Routine Maintenance Routine Maintenance The Chiller is designed to require a minimum of periodic maintenance. Condenser, Air Vents and Reusable Filter The condenser, the air vents, and reusable filter should be kept free of dust and dirt. They should be checked on a regular basis and cleaned as required. The reusable filter is accessed from either the left or right side of the unit. -
Page 27: Temperature Calibration
Temperature Calibration At times, there may be a minor temperature difference between the Chiller’s displayed temperature and the actual temperature as determined by a certified temperature measurement device. There may also be situations where you want the displayed temperature to match a particular value to have standardization between different instruments. -
Page 28: Flow Rate Calibration (Fc)
6. Rotate the Select/Set Knob until the desired calibration offset is displayed. Press the Select/Set Knob or simply allow the display to time out to accept the displayed value. Flow Rate Calibration (Fc) NOTE: Your Chiller's flow rate is calibrated at the factory at the nominal flow rate for the installed pump. Further adjustment is not necessary. -
Page 29: Troubleshooting
Troubleshooting Many problems can be resolved by restoring the factory defaults. If this solves the problem, be careful when restoring your operational settings in order not to repeat the problem. To restore the factory default settings: 1. Place the Power Switch / Circuit Breaker on the rear of the unit in the OFF position. 2. -
Page 30: Diagnostic Mode
Problem Possible Causes Corrective Action Fault code 11 on display Internal probe failure Contact service representative. Fault code 12 on display Loose external probe Check and correct as required. connection Faulty external temperature Replace as required. probe NOTE: Chiller may be operated using internal probe until problem is corrected. -
Page 31: Technical Information
Technical Information Controller Specifications Temperature Set Point Resolution ±0.1°C Temperature Stability ±0.5°C (±0.9°F) Temperature Units °C or °F Pressure Units PSI or kPa Pressure Display Resolution 1 PSI / 0.1 kPa Flow Rate Units GPM or LPM Flow Rate Display Resolution 0.1 GPM / 1 LPM Performance Specifications Model... -
Page 32: Electrical Specifications
Electrical Specifications 110-392... -
Page 33: Pump Performance
Pump Performance P4 3.5 GPM Positive Displacement 1.5 HP Pumps P6 4 GPM Positive Displacement P4 P6 P9 2.33 GPM Positive Displacement M5 Mag Drive Centrifugal T2 1/3 HP Turbine T5-T6-T7-T8 3/4 HP Turbine T9-TE 1 HP Turbine S1 Speck Pump 7.5 GPM 3/4 HP 1 HP Specifications subject to change without notice. -
Page 34: Rs-232 / Rs-485 Communications
RS-232 / RS-485 Communications Serial Connector — A 9-pin D-connector (optional) is provided on the back panel of the Chiller for RS232 / RS485 data communication. A serial cable that uses only the following pins should be used to connect the Chiller to the computer: RS-232 RS-485... -
Page 35: Certificate Of Compliance
Certificate of Compliance All Chillers are tested after assembly to ensure that the product meets or exceeds published mechanical and safety specifications as well as your satisfaction. The Certificate of Compliance is included with the Chiller. The following graph explains the steps involved in a typical test. T emperature Profile 40.00 35.00... -
Page 36: Replacement Parts
Replacement Parts Description Part Number Controller PCB NOTE: When replacing the Controller PCB, it is important to note the software version. You Varies with software can obtain the software version by pressing and holding the Power Button on the controller options while the unit is in “Standby”. -
Page 37: Pumps
Description Part Number Relay, Compressor, COP#040-0166-15, COP#040-0166-15 750-338 PCB, 4-20mA Set Point Control 500-342 High Pressure Control, Penn#P100CC-9C, 275/175 215-473 Compressor Pressure Regulator Valve, SP#CRO-T-6-30/110-5/8ODF 750-766 Valve, Solenoid, Refrigeration, Liquid and Hot Gas Bypass, PK#DS1100,240VAC 750-179 Filter Dryer, SP#C-053-S, 3/8ODF 750-075 Air Filter, Condenser 750-387... -
Page 38: Warranty
Warranty NOTE: The warranty applies only to the original end user and cannot be transferred or sold to another end user without written consent from the manufacturer. The manufacturer’s warranty is one year for parts and labor and two years for parts. Please contact your supplier for additional warranty details and service contract information. -
Page 39: Appendix
Appendix Flow Schematic - All Models 110-392... -
Page 40: Electrical Diagram - 208-230V / 1Ph / 50-60Hz Models Without Heater Option
Electrical Diagram – 208-230V / 1PH / 50-60Hz Models without heater option 110-392... -
Page 41: Electrical Diagram - 208-230V / 1Ph / 50-60Hz Models With Heater Option
Electrical Diagram – 208-230V / 1PH / 50-60Hz Models with heater option 110-392... -
Page 42: Electrical Diagram - 208-230V And 380-460V / 3Ph / 50-60Hz Models Without Heater Option
Electrical Diagram – 208-230V and 380-460V / 3PH / 50-60Hz Models without heater option 110-392... -
Page 43: Electrical Diagram - 208-230V And 380-460V / 3Ph / 50-60Hz Models With Heater Option
Electrical Diagram – 208-230V and 380-460V / 3PH / 50-60Hz Models with heater option 110-392... -
Page 44: Options
Options General Options Wiring Status Alarm (STA): Relay is energized when Chiller is running normally. Relay is de-energized when a fault condition is detected or the unit is placed in Standby. Remote ON/OFF: RCV = Chiller turns OFF when 12-24V AC or DC signal is applied. RCS = Chillers turns OFF when contacts are closed. -
Page 45: Di Control Wiring
DI Control Wiring H2 & H3 Option Wiring H2 = 24 VDC H3 = 12 VDC 110-392... -
Page 46: 4-20 Ma Set Point Control
Go to menu item “CC” and set to “YES”. If current input is outside of the range of the 4–20 mA, “Ft 18” will be displayed. Manufactured by: PolyScience 6600 W. Touhy Avenue Niles, IL 60714 U.S.A. 1-800-229-7569 ● 1-847-647-0611...
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