FTS MAXI-COOL Operator's Manual
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FTS MAXI-COOL Operator's Manual

Recirculating chiller with edc control
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ECIRCULATING
HILLER
PERATOR
S
ANUAL
M
-C
AXI
OOL
with EDC Control

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  • Page 1 ’ ECIRCULATING HILLER PERATOR ANUAL with EDC Control...
  • Page 3 Copyright © 2012 SP Scientific. All marks herein are used under license. All brand or product names mentioned may be trademarks or registered trademarks of their respective companies. Part Number MNL-044-A Rev 007, 04/12 SP Scientific 815 State Route 208 3538 Main Street Gardiner, NY 12525 USA Stone Ridge, NY 12484...

  • Page 4: Important Symbols

    Important Symbols WARNING! INJURY OR EVEN DEATH MAY RESULT IF A CRUSH HAZARD. KEEP HANDS RECOMMENDATION MARKED CLEAR WHEN OPERATING DOOR. WITH THIS SYMBOL IS NOT HEEDED. CORROSIVE CHEMICAL. WEAR ELECTRIC SHOCK DANGER! SUITABLE GLOVES, SAFETY USE APPROPRIATE CAUTION GLASSES, AND PROTECTIVE TO AVOID INJURY OR DEATH.

  • Page 5: Warranty Information

    Please take this opportunity to locate the serial tag on your new Maxi-Cool and record the information below for future reference. SP Scientific also recommends that you complete and return your unit’s warranty registration card.
  • Page 6 Rev 007, 04/12 © SP Scientific 2012...

  • Page 7: Table Of Contents

    Contents Important Symbols ............................... ii Safety Warnings ..............................ii Warranty Information ............................iii Introduction ......................... 1 Overview ................................1 Key Features ..............................1 Installation and Startup ....................3 Initial Inspection ..............................3 Setup ................................... 4 Physical Location ............................4 Ambient Air Requirements ..........................4 Water Requirements ............................
  • Page 8 Contents Maxi-Cool Proportional Control Menu ..........................21 SPAN Menu ............................... 22 Miscellaneous Menu ............................23 Communications Menu ............................24 PID Tuning ................................. 25 It and dt ................................. 26 CCt ................................26 CPb ................................27 Maintenance ......................29 Lockout/Tagout Procedure ..........................29 Removal of Panels ............................

  • Page 9: Introduction

    Chapter Introduction Overview The Maxi-Cool is a portable, caster mounted recirculating chiller system that provides temperature controlled fluid over a wide range. All SP Scientific chillers feature innovative design, high-quality construction, and highly dependable components. This chiller will reliably serve your cooling needs for years to come.
  • Page 10 Introduction Maxi-Cool Rev 007, 04/12 © SP Scientific 2012...

  • Page 11: Installation And Startup

    Installation and Startup Initial Inspection Your Maxi-Cool chiller was carefully packed and thoroughly inspected before leaving the SP Scientific factory. However, in the unlikely event that shipping damage has occurred, retain all packing material and contact your freight carrier immediately.

  • Page 12: Setup

    Expect reduced reliability. Warranty may be voided Not Acceptable. Warranty will be Voided. Over 85°F (Over 29.5°C) NEVER OPERATE THE MAXI-COOL IN AN AREA WITH AN AMBIENT TEMPERATURE ABOVE 32°C (90°F). Water Requirements If your unit is water cooled it will require 2-3 gpm of clean utility water at 30-60 psi., at a temperature of 13°C to 22°C.

  • Page 13: Electrical Requirements

    Maxi-Cool Installation and Startup Electrical Requirements The voltage and frequency requirements are specified on the serial tag on the rear of the unit. Standard variances in frequency (+/-3Hz) and voltage (-5%, +10%) are allowed. CAUTION! IF YOU ARE UNSURE ABOUT THE AVAILABLE ELECTRICAL VOLTAGE SUPPLY IN YOUR FACILITY, CONSULT A QUALIFIED ELECTRICIAN.

  • Page 14: Selecting A Process Fluid

    Installation and Startup Maxi-Cool Selecting a Process Fluid This recirculator is designed for operation with a host of industry standard fluids. The fluid you choose will depend on what temperature range is required. Ethylene Glycol and water (60/40 mix) is an inexpensive and readily available fluid for –25°C to +60°C.

  • Page 15: General Properties Of Process Fluids

    Maxi-Cool Installation and Startup General Properties of Process Fluids Expansion/Contraction It is important to note that some fluids expand as much as 14% from +25°C to +125°C. Do not confuse contraction of the fluid for fluid losses. Fluid Creep Fluids will find any non-sealed connection.

  • Page 16: Unit Check

    Installation and Startup Maxi-Cool Unit Check Short Circuit Hose Hook-Up The input and output connections for the process fluid have 1/2” male pipe threads on them. Use a short hose (1/2” ID) to connect the process fluid outlet directly to the inlet.

  • Page 17: Removal Of Panels

    Maxi-Cool Installation and Startup Removal of Panels Ensure the power is turned off (rocker switch to EMO (O)). Loosen and remove screws along edges of the panels. Pull off panels and place them out of the way. Place a piece of clean cardboard under the unit.

  • Page 18: Installation

    Installation and Startup Maxi-Cool Installation Add Fluid CORROSIVE CHEMICAL!. WEAR SUITABLE GLOVES, SAFETY GLASSES, AND PROTECTIVE CLOTHING. WEAR SAFETY GLASSES. Remove reservoir lid Fill reservoir to 1” (2.5cm) from the top Replace and tighten lid. Move the rocker switch on the front panel to the ON (I) position, the amber POWER light should illuminate.
  • Page 19 Maxi-Cool Installation and Startup Rev 007, 04/12 © SP Scientific 2012...

  • Page 20: Optional High Pressure Bypass Hook-Up

    Installation and Startup Maxi-Cool Now that the unit has its cooling medium, it is time to tie the hook the unit up to your process. But first: Press the I/O button to shut off the pump. Move the rocker switch to the EMO (O) position.

  • Page 21: Connect To The Process

    Maxi-Cool Installation and Startup Connect to the Process SP Scientific provides input and output connections for the process fluid. To tie these lines into your process, you will require  1/2” Fittings (for 1/2” male pipe thread1/2” ID tubing (minimum) ...

  • Page 22: Prime The Fluid Loop

    Installation and Startup Maxi-Cool Prime the Fluid Loop At this point your unit should be hooked up to the proper electrical service and all plumbing necessary for operation should be in place and sealed. Make sure the drains are CLOSED.

  • Page 23: Operation

    Chapter Operation System Preparation Move rocker switch to the POWER position. System is now in Idle. Display will be blank and the amber Power light will be illuminated Basic Operation Start Up Press I/O button Display flashes SP (setpoint) then the current setpoint temperature (the setpoint is the temperature at which the unit will maintain the fluid temperature).

  • Page 24: Control

    Operation Maxi-Cool Control When the system is running touch the button to bring up the setpoint. Adjust the setpoint using the keys. The setpoint is automatically accepted after 4 seconds. Note: When changing the setpoint, loosen the red vent screw on the reservoir lid to accommodate for the expansion/contraction of the process fluid.

  • Page 25: High Pressure Bypass Adjustment

    Maxi-Cool Operation 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 Rev 007, 04/12 © SP Scientific 2012...

  • Page 27: User Menu

    Chapter User Menu Overview This unit is equipped with an EDC digital control package. Varying the parameters in the EDC Controller’s User Menu allow the operation of the unit to be fine-tuned to meet the needs of a specific application. A variety of parameters such as Ramp Rate, Auto-Power Recovery, 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.

  • Page 28: Operating Mode

    User Menu Maxi-Cool Operating Mode Once a menu pathway has been completed, you are returned to the operating mode. Operating Mode (Unit is running or in IDLE) SPAN Proportional Miscellaneous Communication Span Menu Control Menu Menu Menu PLOC baud Ramp Rate...

  • Page 29: Proportional Control Menu

    Maxi-Cool User Menu Proportional Control Menu Ramp Rate. Programmed transition rate from old setpoint to new setpoint, in degrees per rr 0.0 minute. Ramp Rate is more of a slew limiter, because the available ramp rate is obviously limited by the thermal load and the pull-down capacities of the refrigeration system.

  • Page 30: Span Menu

    User Menu Maxi-Cool SPAN Menu High Alarm. An alarm can be set to alert the user that the process temperature is too high. Should the HA be triggered, the system will go to FULL COOL and the display will flash HA.

  • Page 31: Miscellaneous Menu

    Maxi-Cool User Menu Miscellaneous Menu Parameter Lock. 0=off, 1=on. If PLOC is set to 0, the PID settings may be changed during idle or while the system is running, thus allowing system adjustment. If PLOC is set PLOC to 1, then the PID can only be adjusted during the IDLE state and cannot be set while the Parameter Lock system is running.

  • Page 32: Communications Menu

    User Menu Maxi-Cool Communications Menu Baud Rate. For the RS-232 control communications port may be set according to the table. baud Display Baud Baud Rate 1200 2400 9600 Sbit Stop Bit. Parameter that may be selected (1, 1.5, 2). Stop Bit dAtA Data Word.

  • Page 33: Pid Tuning

    Maxi-Cool User Menu PID Tuning Each installation has different conditions of operation (ambient temperature, water temperature, different fluid loop length, etc.), therefore the factory PID settings do not always provide optimum control at the required temperature setpoint. Use the instructions outlined below and adjust the PID settings to the values shown at below.

  • Page 34: It And Dt

    User Menu Maxi-Cool It and dt Measure the period of the temperature oscillations, peak temperature to peak temperature. Integral Time =It = Derivative Time = dt= Example: Time Program the results into the controller using the instructions outlined in PID tuning.

  • Page 35: Cpb

    Maxi-Cool User Menu Note the amount the temperature swings above and below the setpoint. The temperature swing is used to figure the proportioning band. Cool Proportioning Band (CPb) = Temperature swing below setpoint + 10% of that temperature swing Example: CPb = 2°C + 10% of 2°C = 2 + 0.2 = 2.2...
  • Page 36 User Menu Maxi-Cool Rev 007, 04/12 © SP Scientific 2012...

  • Page 37: Maintenance

    Chapter Maintenance WARNING! INJURY OR EVEN DEATH MAY RESULT IF A RECOMMENDATION MARKED WITH THIS SYMBOL IS NOT HEEDED. ELECTRIC SHOCK DANGER! USE APPROPRIATE CAUTION TO AVOID INJURY OR DEATH. BURN DANGER! POTENTIALLY HOT SURFACE. USE APPROPRIATE CAUTION. ALWAYS REMOVE POWER FROM THE UNIT BEFORE PERFORMING MAINTENANCE PROCEDURES.

  • Page 38: Removal Of Panels

    Maintenance Maxi-Cool Removal of Panels Ensure the power is turned off, move the breaker on the back of the unit to the OFF position and push in the EMO on the front panel. Loosen the screws along the back edge of the side panels.

  • Page 39: Fuse Replacement

    Maxi-Cool Maintenance 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 Rev 007, 04/12 © SP Scientific 2012...

  • Page 40: Cleaning

    Maintenance Maxi-Cool Cleaning The following procedure should be followed on a routine basis, from weekly to monthly depending upon the operating environment. Disconnect electric utilities. Wipe down all exterior cabinet surfaces with a damp cleaning cloth. Check switch for proper operation.

  • Page 41: Edc Programmer's Reference

    Chapter EDC Programmer’s Reference Overview The MPC and EDC controllers are used in a variety of cooling products manufactured by SP Scientific. The commands used by a specific system will vary per the descriptions at the end of this reference, but the operational aspects, hardware and software of the interface are consistent across the product line.

  • Page 42: Communications

    EDC Programmer’s Reference Maxi-Cool Communications Communication operates at a user definable BAUD rate selectable from 300, 1200, 2400, 9600. Parity may be odd, even, or none. The interface uses one Start bit and either one, one-and-a-half, or two Stop bits (user selectable). Data word length is selectable at 7 bit data with designated parity, or 8-bit data without parity.
  • Page 43 EDC Programmer’s Reference Maxi-Cool A data string must be terminated by a "Carriage Return" (ASCII 013 decimal / 0D hex)."Line Feed" (ASCII 010 decimal / 0A hex) may be optionally inserted by the host, but will be ignored. A "line" may not exceed 128 characters.

  • Page 44: Transmitted Data

    EDC Programmer’s Reference Maxi-Cool The number of characters attached to the "value" 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.
  • Page 45 EDC Programmer’s Reference Maxi-Cool Error Message: receipt of a message that is syntactically incorrect, exceeds system limits, or is otherwise faulty (such as Parity Error), will result alternately in an error message. Parameter Message: in response to a query, the parameter and its value will be returned to the host.

  • Page 46: Transmitted Data Format

    EDC Programmer’s Reference Maxi-Cool Transmitted Data Format Acknowledge The explicit characters "OK" acknowledge receipt of a valid message, followed by 11 spaces (not counting the space for line continuation, described below). Error The line begins with the character "E", followed by a 3-digit decimal value defining the error number.

  • Page 47: Terminator

    EDC Programmer’s Reference Maxi-Cool Values for system characteristics which are not programmable parameters: e.g., switches, on/off status, etc., will be returned as byte status. In other words, if the state is "true", the returned value will be +0000255 (byte true hex FF); if the queried status is false, or off, the returned value will be +0000000 (byte false hex 00).
  • Page 48 EDC Programmer’s Reference Maxi-Cool  CASC? (Service Use) {F004} Report the existence of a two-stage refrigeration system (0=single compressor, 1=cascade).  CBLI? (Service Use) {F005} Report the configuration of cool/bypass/liquid injection valves in a given system configuration.  CCT= / CCT? {F006} Set or query the Cool Cycle Time: the on/off period assigned to the proportioning cooling valves, in seconds.
  • Page 49 EDC Programmer’s Reference Maxi-Cool  DP= / DP? {F017} Set or query the use of integer/decimal format on the control panel display. 0 (decimal point off) displays temperature rounded to the nearest integer; 1 (decimal point on) displays temperature with 0.1 resolution.
  • Page 50 EDC Programmer’s Reference Maxi-Cool  HYSTST2? (Service Use) {F029} Query the hysteresis, in degrees, applied to measurement of the cascade condenser (first refrigeration stage output), for operation of the second-stage refrigeration.  IT= / IT? {F030} Set or query the [integral] time constant, in seconds, applied to the adjustment of the proportioning band, governing the automatic reset ("droop"...
  • Page 51 EDC Programmer’s Reference Maxi-Cool  PARITY? {F039} Query the parity setting of the communication link. 0 = no parity, 1 = odd, 2 = even.  PF= / PF? {F040} Set or query the selection of the automatic power recovery algorithm. 0 = disabled, 1 = enabled.
  • Page 52 EDC Programmer’s Reference Maxi-Cool  REV? {F052} Query [embedded] software revision level in system program ROM.  Command to restore factory-determined calibration constants.  RR= / RR? {F054} Set or query setpoint transition rate (Ramp Rate), in degrees per second.
  • Page 53 EDC Programmer’s Reference Maxi-Cool  TRIPST2? (Service use) {F068} Query trip temperature, in degrees, of cascade condenser, for turn-on of the second stage refrigeration.  UPHOURS? {F069} Query total hours of system operation (including off), from engagement of Emergency Off switch.

  • Page 54: Alarm Codes

    EDC Programmer’s Reference Maxi-Cool Alarm Codes Numeric codes are returned to the query ALMCODE? per the following alarm conditions. Alarms, once set, are maintained until explicitly cleared, even if the alarm condition has been corrected.  MPC/EDC Code 0: No outstanding alarm condition.

  • Page 55: Rs-232 Error Codes

    EDC Programmer’s Reference Maxi-Cool RS-232 Error Codes The following error codes are returned Ennn if the parser/syntaxer/limits-checking software finds fault with the received string. Group 0: UART Transmit/Receive and General Receive errors.  E001 UART Overrun. Character received by UART before previous character has been retrieved from the character input buffer.
  • Page 56 EDC Programmer’s Reference Maxi-Cool Group 2 Errors: Command Parsing Errors  E020 Undefined String. Character string not identified as valid command, in position indicated by trailing argument.  E021 Illegal Character. Character in string not a recognized character (A-Z, a-z, 0-9, "=", "?", ".", "+", "-", <SP>...
  • Page 57 EDC Programmer’s Reference Maxi-Cool Group 4: Operational and Miscellaneous Errors  E040 Not Yet Implemented. Use of a command that is defined to the parser but not presently implemented by SP Scientific.  E041 Stop Error. System already stopped has received a "STOP" command.

  • Page 58: Sample Program

    EDC Programmer’s Reference Maxi-Cool Sample Program The following program is supplied to assist in troubleshooting should the user’s attempts to communicate via the RS-232 be unsuccessful. It will execute properly from either GWBASIC or QBASIC on an IBM-compatible PC. If this program runs, the alternate driver has a software or configuration problem.

  • Page 59: Appendix A: Troubleshooting

    Appendix Appendix A: Troubleshooting CAUTION! ONLY QUALIFIED PERSONNEL SHOULD PERFORM MAINTENANCE ON THE REFRIGERATION SYSTEM, AND ONLY EPA CERTIFIED TECHNICIANS SHOULD EVACUATE OR CHARGE REFRIGERANTS. Problem Possible Cause Solutions Power is not connected Have electrician check power connections properly Breaker at the wall is in the Unit will not start Turn breaker "on".
  • Page 60 Appendix A: Troubleshooting Maxi-Cool CAUTION! ONLY QUALIFIED PERSONNEL SHOULD PERFORM MAINTENANCE ON THE REFRIGERATION SYSTEM, AND ONLY EPA CERTIFIED TECHNICIANS SHOULD EVACUATE OR CHARGE REFRIGERANTS. Problem Possible Cause Solutions Check so see that all lines have adequate insulation, Heat load is above unit’s rating and that there are no local sources of heat that may be contributing to the load.
  • Page 61 Maxi-Cool Appendix A: Troubleshooting CAUTION! ONLY QUALIFIED PERSONNEL SHOULD PERFORM MAINTENANCE ON THE REFRIGERATION SYSTEM, AND ONLY EPA CERTIFIED TECHNICIANS SHOULD EVACUATE OR CHARGE REFRIGERANTS. Problem Possible Cause Solutions The pump motor is provided with a thermal overload protection. If it overheats, the pump will shut down; it will restart when the motor has cooled down.
  • Page 62 Appendix A: Troubleshooting Maxi-Cool Problem Possible Cause Solutions The overtemp is factory set for protection of the Fluid operating above equipment. DO NOT READJUST WITHOUT SP overtemp set point. SCIENTIFIC SERVICE AUTHORIZATION. No heating: Standard models do not have Overtemp sensor open or not...

  • Page 63: Appendix B: System Safeties And Alarms

    Appendix Appendix B: System Safeties and Alarms Low Fluid Level The Low Fluid Level indicator and the Alarm Lamp will illuminate, and the buzzer will sound. (based on the value set for the nOIS parameter in the Miscellaneous Menu) When the fluid level drops below the float, the pump and refrigeration are automatically stopped to prevent Report damage to the chiller.
  • Page 64 Appendix B: System Safeties and Alarms Maxi-Cool High Fluid Temperature The display will flash HA, an audible alarm is sounded (depending on the nOIS setting), and the system will go to FULL COOL. The pump and compressor will disengage if the condition Report persists for more than 30 seconds.
  • 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...

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