Conair PCW-1.5 User Manual
  1. Manuals
  2. Brands
  3. Conair Manuals
  4. Chiller
  5. PCW-1.5
  6. User manual

Conair PCW-1.5 User Manual

Portable chillers
Hide thumbs
Table of Contents

Advertisement

Quick Links

Download this manual
U S E R G U I D E
UGH024-0907
Portable Chillers
Water-cooled models PCW-1.5 to PCW-30
and Air-cooled models PCA1.5 to PCA-30
INTRODUCTION
•
Purpose of the User Guide
Read this so no one gets hurt
•How it works
•
Specifications: Portable Chillers
Preparing for installation
•
•
Connecting the main power source
pressor
•
Checking the sight glass
Stopping the chiller
•
OPERATION
the chiller
•
Changing settings
•
Running/stopping the chiller
Corporate Office: 412.312.6000
•
How the guide is organized
•
DESCRIPTION
•
What is the Portable Chiller?
•
INSTALLATION
Making process plumbing connections
•
Checking electrical connections
•
Initially warming the chiller
•
TIC control features
•
Changing the setpoint temperature
•
Viewing chiller status screens
l
Instant Access 24/7 (Parts and Service): 800.458.1960
•
Your responsibilities as a user
•
Typical applications
•
Unpacking the boxes
•
Filling the chiller
•
•
Checking pump rotations
•
Checking for leaks
•
PLC control features
•
Before starting
•
Menu features
•
Tuning the chiller
•
Programming settings
l
Parts and Service: 814.437.6861
www.conairnet.com
•
ATTENTION:
•
Limitations
•
Warnings and cautions
Checking the refrigerant charge
•
Checking the com-
•
Initially running the chiller
•
Starting/stopping
•
Powering up
•
Changing setpoint
•
•
•

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the PCW-1.5 and is the answer not in the manual?

Questions and answers

Related Manuals for Conair PCW-1.5

Summary of Contents for Conair PCW-1.5

  • Page 1 U S E R G U I D E UGH024-0907 Portable Chillers Water-cooled models PCW-1.5 to PCW-30 and Air-cooled models PCA1.5 to PCA-30 INTRODUCTION • Purpose of the User Guide • How the guide is organized • Your responsibilities as a user •...
  • Page 2 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 damages in connection with the furnishing, performance or use of this information. Conair makes no warranty of any kind with regard to this information, including, but not limited to the implied warranties of merchantability and fitness for a particular purpose.

  • Page 3: Table Of Contents

    Ta b l e o f C o n t e n t s I n t r o d u c t i o n Purpose of the user guide ....... . 1-2 How the guide is organized .
  • Page 4 Checking the compressor ....... 3-13 Checking the water level gauge ......3-13 PLC CONTROL Initially warming the Chiller.
  • Page 5 Setting discharge pressure setpoint ..... . . 4-29 Setting PID values ........4-30 Manually starting/stopping the pump .
  • Page 6 PLC control alarm problems ......6-25 Checking and replacing switches ....6-37 Replacing the RTD.
  • Page 7 S E C T I O N I n t r o d u c t i o n P u r p o s e o f t h e u s e r g u i d e ....1 - 2 H o w t h e g u i d e i s o r g a n i z e d .

  • Page 8: I N T R O D U C T I O N

    P u r p o s e o f t h e U s e r G u i d e This User Guide describes Conair’s Portable Chillers and explains step- by-step how to install, operate, maintain and repair this equipment.

  • Page 9: Your Responsibilities As A User

    Yo u r R e s p o n s i b i l i t y a s a U s e r You must be familiar with all safety procedures concerning installation, opera- tion and maintenance of this equipment. Responsible safety procedures include: •...
  • Page 10 AT T E N T I O N : R e a d t h i s s o n o o n e g e t s h u r t We design equipment with the user’s safety in mind. You can avoid the potential hazards identified on this machine by following the procedures outlined below and elsewhere in the User Guide.
  • Page 11 Water-cooled units require a minimum of one foot clearance around the perimeter for service-ability. Conair recommends two feet for ease of servicing. Air-cooled units require a minimum of two feet clearance around the perimeter for service-ability and proper air flow.
  • Page 12 1 - 6 l I n t r o d u c t i o n...

  • Page 13: D E S C R I P T I O N

    S E C T I O N D e s c r i p t i o n W h a t i s t h e Po r t a b l e C h i l l e r ? ... . 2 - 2 Ty p i c a l a p p l i c a t i o n s .

  • Page 14: What Is The Portable Chiller

    20°F to 65°F {7°C to 18°C}. For applications requiring 40°F and lower mix glycol with the water to the correct percentage. Conair Portable Chillers are designed to provide chilled fluid for industrial applications requiring 24-hour-a-day performance. Units are totally self-con- tained for easy, economical installation.

  • Page 15: Typical Applications

    Ty p i c a l A p p l i c a t i o n s The Conair Portable Chillers can be used anywhere a reliable source of process cooling water - with stable temperature control - is required.

  • Page 16: H O W I T Wo R K S : Wa T E R- C O O L E D

    H o w i t Wo r k s : Wa t e r- c o o l e d p o r t a b l e c h i l l e r s Process circulation Size 1 Size 2 Hot fluid from the process enters the chiller through the...

  • Page 17: How It Works: Water-Cooled Portable Chillers

    H o w i t Wo r k s : Wa t e r- c o o l e d p o r t a b l e c h i l l e r s Refrigerant circulation The evaporator extracts heat from the process fluid, causing the refrigerant to vaporize (evap- orate) into a gas.

  • Page 18: How It Works: Air-Cooled Portable Chillers

    H o w i t Wo r k s : A i r- c o o l e d p o r t a b l e c h i l l e r s Process circulation Size 1 Size 2 Hot fluid from the process enters the chiller through the From Process connection into the pump reservoir.
  • Page 19 H o w i t Wo r k s : A i r- c o o l e d p o r t a b l e c h i l l e r s Refrigerant circulation The evaporator extracts heat from the process fluid, caus- ing the refrigerant to vaporize (evaporate) into a gas.

  • Page 20: Portable Chiller Features

    Po r t a b l e C h i l l e r f e a t u r e s Water-cooled models Size 1 Size 2 with recirculation pump (dual pump chiller) Hot Gas Bypass valve Relief valve Condenser Compressor Receiver...
  • Page 21 Po r t a b l e C h i l l e r f e a t u r e s Air-cooled models Size 1 Size 2 Hot Gas Bypass valve Condenser Compressor Receiver Process pump Pump reservoir Evaporator Recirculation pump Filter Dryer TX valve...

  • Page 22: Pump Curves

    These pump curves are non-overloading using the service factor of the motors. SPECIFICATION NOTES: Specifications may change without notice. Check with your Conair representative for the most current information. *These pump curves are non-overloading using the service factor of the motors.
  • Page 23 SPECIFICATION NOTES: *These pump curves are non-overloading using the service factor of the motors. Specifications may change without notice. Check with your Conair representative for the most current information. UGH024-0607 D e s c r i p t i o n l...
  • Page 24 2 - 1 2 l D e s c r i p t i o n...

  • Page 25: I N S T A L L A T I O N

    S E C T I O N I n s t a l l a t i o n U n p a c k i n g t h e b o x e s ....3 - 2 Wa r n i n g s a n d c a u t i o n s .

  • Page 26: Unpacking The Boxes

    CAUTION: Lifting Conair Portable Chillers are designed to easily roll on casters. If, for some reason you need to lift the chiller, take all precautions to avoid personal injury or damage to the chiller. Lift the chiller using a forklift or hoist with straps that have been positioned at the chillers’...

  • Page 27: Warnings And Cautions

    Wa r n i n g s a n d C a u t i o n s W A R N I N G : I m p r o p e r i n s t a l l a t i o n , o p e r a t i o n , o r s e r v i c i n g m a y r e s u l t i n e q u i p m e n t d a m a g e o r p e r - s o n a l i n j u r y.

  • Page 28: Preparing For Installation

    P r e p a r i n g f o r I n s t a l l a t i o n Plan the location for the chiller and prepare the area properly. Position the chiller as close to the process machine as possible. Place the chiller in position near the process machine so that fluid lines can be connected from the process machine to the chiller and back.
  • Page 29 M a k i n g P r o c e s s P l u m b i n g C o n n e c t i o n s Warm fluid from process equipment enters the chiller at the From Process connec- tion and chilled fluid returns to the process equipment through the To Process con- nection.

  • Page 30: Making Process Plumbing Connections

    M a k i n g P r o c e s s P l u m b i n g C o n n e c t i o n s ( c o n t i n u e d ) For the Water-cooled Chillers connect the water source for cooling to the Condenser Water inlet on the back of the chiller.
  • Page 31 M a k i n g P r o c e s s P l u m b i n g C o n n e c t i o n s ( c o n t i n u e d ) Size 1 Cabinet Air Cooled From process To process...

  • Page 32: Filling The Chiller

    F i l l i n g t h e C h i l l e r The chiller is shipped without coolant. The chiller is filled manually during instal- lation. Use water as the coolant down to 40°F {4°C}. Below 40°F and down to 20°F {-7°C}, use an ethylene glycol or propylene glycol and water solution (see Percent Glycol vs.
  • Page 33 F i l l i n g t h e C h i l l e r ( c o n t i n u e d ) To fill with glycol solution: Mix the glycol to the proper percentage. Use the table to determine the per- centage (by volume) of glycol needed for the process temperature (in °F) you require.

  • Page 34: Checking Refrigerant Charge

    This is normal. NOTE: Leaving the air- If the charge is low and the unit is under warranty, contact Conair service. cooled side panels off Otherwise have a local, certified refrigeration technician add refrigerant to the sys- for an extended period tem.

  • Page 35: Connecting The Main Power Source

    C o n n e c t i n g t h e M a i n Po w e r S o u r c e W A R N I N G : I m p r o p e r i n s t a l l a t i o n , o p e r a t i o n , o r s e r v i c i n g m a y r e s u l t i n e q u i p m e n t d a m a g e o r p e r s o n a l i n j u r y.

  • Page 36: Checking Electrical Connections

    C h e c k i n g E l e c t r i c a l C o n n e c t i o n s WA R N I N G : E l e c t r i c a l H a z a r d Before performing any work on this item, disconnect and lock out elec- trical power sources to prevent injury from unexpected energization or startup.

  • Page 37: Tic Control

    T I C C o n t r o l C h e c k i n g P u m p R o t a t i o n Press the on/off and enter buttons simultaneously to turn on Pump. Press the on/off and enter buttons simultaneously to turn off pump.

  • Page 38: Plc Control

    Turn on main power source. The control boots up and when finished, the screen displays “Press enter to continue.” Press enter. This screen will appear. Conair Chiller PCW - 30 123456 Press next. The screen displays information about the chiller, which includes the model, series, size, and serial number.
  • Page 39 Pump should now be turning clockwise. If an alarm occurs, see Answering Alarms, in the Troubleshooting section. If alarm continues or reoccurs, call your Conair Service representative. Press the Escape/Previous Screen button 2 times, or if following the sequence of this manual continue with the instructions on the next page.

  • Page 40: Checking For Leaks

    P L C C o n t r o l C h e c k i n g f o r L e a k s After checking pump rotation, continue with startup by checking the chiller for leaks. Do this by turning on only the pump from the control and letting the pump run while checking the inside of the chiller.

  • Page 41: Initially Starting The Chiller

    P L C C o n t r o l I n i t i a l l y S t a r t i n g t h e C h i l l e r Only after you have checked for leaks and checked for pump rotation should you start the chiller.

  • Page 42: Stopping The Chiller

    S t o p p i n g t h e P L C C h i l l e r To stop the chiller, press the Stop button on the control panel. Run Stop Manual The compressor shuts off after a pumpdown and the pump shuts off 10 seconds later.

  • Page 43: O P E R A T I O N

    S E C T I O N O p e r a t i o n T I C c o n t r o l f e a t u r e s ....4 - 2 P L C c o n t r o l f e a t u r e s .

  • Page 44: Tic Control Features

    T I C C o n t r o l Fe a t u r e s The TIC control lets you view the status of the chiller and change settings. Display 3-digit screen shows Process temperature, Alpha Alarms and Operation indicators.
  • Page 45 P L C C o n t r o l Fe a t u r e s Display Screen Shows status, setup and run modes Up / Down Scroll Arrows Option Arrows Scroll through the display Choose parameters dis- Status Lights played on the screen screens Show the status of the compres-...

  • Page 46: Before Starting

    B e f o r e S t a r t i n g Before you start daily operation of the chiller, you need to perform scheduled pre- ventative maintenance. Necessary maintenance is described in the Maintenance section of this Users Guide. WA R N I N G : E l e c t r i c a l H a z a r d Before performing any work on this item, disconnect and lock out electrical power sources to prevent injury from unexpected energization or startup.
  • Page 47 G e n e r a l T I C C o n t r o l Fe a t u r e s Menus on the Controller: The controller has information available in 5 areas. Four of them are user accessi- ble.
  • Page 48 R e s e t t i n g t h e T I C C o n t r o l a n d Po w e r U p When powered, the chiller control automatically performs a bootup routine. When the bootup routine is complete, the display will alternate between “rst”...

  • Page 49: Starting/Stopping The Chiller

    Settings are factory preset and will fit most applications. Once your system param- eters are established these values are rarely accessed and changed. If you have any problems or questions, see the next few sections, or call your Conair Service repre- sentative.
  • Page 50 T I C C o n t r o l C h a n g i n g t h e Te m p e r a t u r e U n i t s ( U N ) The Temperature units parameter allows selection of the displayed temperature units.
  • Page 51 T I C C o n t r o l C h a n g i n g t h e P r o c e s s Va r i a b l e ( P U S ) The Process variable selector allows the operator to select the controlled temperature from the following: To Process, From Process and Average.

  • Page 52: Setup Menu

    T I C Tu n i n g t h e C h i l l e r ( P i T ) C o n t i n u e d Fast Responding System: Select the fast setting “FSt” for small systems. Less than 250 pounds of water {30 gal- lons} and 2,000 pounds of steel might be considered a small system.
  • Page 53 T I C C o n t r o l C h a n g i n g t h e D e v i a t i o n Te m p e r a t u r e I g n o r e Ti m e ( D t t ) The deviation temperature ignore time is the time from when a deviation from set- point is sensed until it is displayed.
  • Page 54 T I C C o n t r o l C h a n g i n g t h e L o w Te m p e r a t u r e A l a r m S e t p o i n t ( S P L ) The low limit temperature alarm setpoint is the setpoint that protects the chiller from undershooting the required process water temperature.
  • Page 55 In this case the alarm silence does nothing and alarms can only be cleared provide adequate control, after the alarm condition is nullified. The range of times that can be programmed is please consult the Conair service to further adapt 0-60 minutes.
  • Page 56 T I C C o n t r o l R e a d i n g t h e S o f t w a r e Ve r s i o n ( c o 1 ) The Version of the software is depicted by the c “xx” parameter. This “read only” parameter and depicts the version of the software that has been downloaded into the controller.
  • Page 57 T I C A l a r m s C o n t i n u e d PAL: (Pressure alarm low) flashes when the low refrigerant pressure switch has sensed low pressure for more than the low pressure ignore time (LP1). This is a cycling alarm up to three times per hour.
  • Page 58 P L C C o n t r o l Po w e r i n g U p Plug in the power cord to restore power after any required maintenance. Turn on the main power. The chiller control automatically performs its bootup routine. The screen displays Press Enter to continue.
  • Page 59 P L C C o n t r o l S e t u p M e n u The PLC control allows you to program various parameters for the Chiller: • Temperature Setpoint The temperature you want the To Process liquid. •...
  • Page 60 P L C C o n t r o l Vi e w i n g R u n M e n u After you have viewed all the Status screens and made any necessary changes to the Setup screens, you are ready to run the Chiller. To run the chiller from the main screen: Press the Run arrow on the Main screen.
  • Page 61 P L C C o n t r o l Vi e w i n g R u n M e n u The Status screens are read-only screens. You cannot make changes to these screens. To view the status screens: The Status button does not Press the Status arrow on the Main screen.
  • Page 62 P L C C o n t r o l Vi e w i n g R u n M e n u C o n t i n u e d Status screens include: Temperature Temperature Displays the To Process temperature and the Setpoint temperature. To change the Setpoint Stat Setup Run Alarm...
  • Page 63 P L C C o n t r o l C h a n g i n g S e t p o i n t Te m p e r a t u r e Use the Temperature Setpoint to set the temperature you want to the water to be exit- ing the chiller at the To Process connection.
  • Page 64 P L C C o n t r o l C h a n g i n g H i g h Te m p e r a t u r e D e v i a t i o n Decide how many degrees above the setpoint you will allow the chiller to deviate before an alarm occurs.
  • Page 65 P L C C o n t r o l S e t t i n g Pe r c e n t G l y c o l To set the percent ethylene glycol or propylene glycol solution, determine the temper- ature of the process fluid you want.

  • Page 66: Setting Percent Glycol

    P L C C o n t r o l S e t t i n g Pe r c e n t G l y c o l C o n t i n u e d Press the UP/Down Scroll arrows to scroll through the setup screens. NOTE: If you are using water as the coolant, set the Percent Glycol to zero on the control.

  • Page 67: Selecting The Temperature Scale

    S e l e c t i n g t h e Te m p e r a t u r e S c a l e You can choose to display the temperature in either Fahrenheit or Celsius. To select the temperature scale: Press the Setup arrow.

  • Page 68: Resetting Pid Settings

    P L C C o n t r o l R e s e t t i n g P I D S e t t i n g s Use the PID reset to return the control to the factory settings. Use this if the autotune does not give good values or good values are lost.

  • Page 69: Setting Fan Setpoints

    P L C C o n t r o l S e t t i n g Fa n S e t p o i n t s For the Air-cooled Portable Chillers you can choose the condenser pressures in PSIG at which the fan cycles on and off.
  • Page 70 P L C C o n t r o l S e t t i n g Fa n S e t p o i n t s Press Enter to save the change. Press the Escape/Previous Screen button to return to the main screen. Fan setpoints are not saved in retentive memory and are lost when power is disconnected.
  • Page 71 P L C C o n t r o l S e t t i n g D i s c h a r g e P r e s s u r e S e t p o i n t You can select the refrigerant discharge pressure setpoints in PSIG.
  • Page 72 P L C C o n t r o l S e l e c t i n g P I D Va l u e s The PID values are set at the factory to default settings. The values should be changed only if the water regulator valve or the VFD are unable to maintain discharge pressure.

  • Page 73: Manually Starting/Stopping The Pump

    P L C C o n t r o l M a n u a l l y S t a r t i n g / S t o p p i n g t h e P u m p To run or stop the pump from the main screen: Press the arrow pointing to Run on the screen.
  • Page 74 4 - 3 2 l O p e r a t i o n...

  • Page 75: M A I N T E N A N C E

    S E C T I O N M a i n t e n a n c e M a i n t e n a n c e f e a t u r e s ....5 - 2 Wa r n i n g s a n d c a u t i o n s .

  • Page 76: Maintenance Features

    M a i n t e n a n c e Fe a t u r e s Conair Series PCA/PCW chillers need regular, scheduled maintenance for peak performance. To maintain the best performance of the chiller, it must be cleaned and inspected regularly.

  • Page 77: Warnings And Cautions

    Wa r n i n g s a n d C a u t i o n s W A R N I N G : I m p r o p e r i n s t a l l a t i o n , o p e r a t i o n , o r s e r v i c i n g m a y r e s u l t i n e q u i p m e n t d a m a g e o r p e r - s o n a l i n j u r y.

  • Page 78: Preventative Maintenance Schedule

    P r e v e n t a t i v e M a i n t e n a n c e S c h e d u l e Daily, or as often as needed To maintain the best perform- Ì...
  • Page 79 P r e v e n t a t i v e M a i n t e n a n c e S c h e d u l e Monthly To maintain the best perform- Ì Inspecting cooling water treatment system ance, follow the maintenance If your chiller uses a cooling water treatment system, maintain proper chemi- schedule and record informa-...

  • Page 80: Plc Control Entering Maintenance Screens

    You must the total cycles or hours since the initial assembly of the chiller. These numbers are have clearance to enter and only reset by Conair Service personnel. To view the cycle information: change settings on these screens.

  • Page 81: Checking Electrical Connections

    C h e c k i n g E l e c t r i c a l C o n n e c t i o n s WARNING: Electrical Hazard Before performing any work on this item, disconnect and lock out electrical power NOTE: Always refer sources to prevent injury from unexpected energization or startup.

  • Page 82: O R Wa T E R- C O O L E D C O N D E N S E R

    C l e a n i n g t h e B r a z e d P l a t e E va p o r a t o r o r Wa t e r- C o o l e d C o n d e n s e r Minerals and other contaminant’s produce deposits, scales, slime, or algae on the heat transfer surfaces exposed to water.

  • Page 83: Cleaning The Air-Cooled Condenser

    C l e a n i n g t h e A i r- C o o l e d C o n d e n s e r WARNING: Electrical Hazard Before performing any work on this item, disconnect and lock out electrical power sources to prevent injury from unexpected energization or startup.

  • Page 84: Checking The Refrigerant Charge

    Under low load conditions, when the hot-gas bypass valves are operating, bubbles may be visible in the sight glass. This is normal. If the charge is low and the Chiller is under warranty, contact Conair service; or have a local, certified refrigeration technician add refrigerant to the system.

  • Page 85: Checking The Reservoir Level

    C h e c k i n g R e s e r v o i r L e v e l WARNING: Electrical Hazard Before performing any work on this item, disconnect and lock out electrical power sources to prevent injury from unexpected energization or startup. Be sure that power to the chiller is OFF when doing any maintenance on the chiller.

  • Page 86: Plc Control Setting Auto Tune Mode

    P L C C o n t r o l S e t t i n g A u t o Tu n e M o d e Use the Auto Tune Mode to maintain the temperature setpoint and minimize over- shooting it.
  • Page 87 P L C C o n t r o l S e t t i n g A u t o Tu n e M o d e C o n t i n u e d The password screen displays. Use the keypad to enter the password.
  • Page 88 5 - 1 4 l M a i n t e n a n c e...

  • Page 89: Tr O U B L E S H O O T I N G

    S E C T I O N Tr o u b l e s h o o t i n g B e f o r e b e g i n n i n g ....6 - 2 A f e w w o r d s o f c a u t i o n .

  • Page 90: Before Beginning

    B e f o r e B e g i n n i n g You can avoid most problems by following the recommended installation, opera- tion and maintenance procedures outlined in this User Guide. If you have a prob- lem, this section will help you determine the cause and tell you how to fix it.

  • Page 91: A Few Words Of Caution

    A Fe w Wo r d s o f C a u t i o n W A R N I N G : I m p r o p e r i n s t a l l a t i o n , o p e r a t i o n , o r s e r v i c i n g m a y r e s u l t i n e q u i p m e n t d a m a g e o r p e r s o n a l i n j u r y.

  • Page 92: Tic Control Answering An Alarm

    T I C C o n t r o l A n s w e r i n g a n A l a r m When an alarm condition occurs, the alarm light on the control panel lights. It stays lit until the alarm condition is corrected.

  • Page 93: Tic Control Problems

    Check the TIC indicator lights and replace as needed. There is a problem with the control The control panel may have failed. panel. Contact Conair Service. (continued) Tr o u b l e s h o o t i n g l 6 - 5...
  • Page 94 T I C C o n t r o l P r o b l e m s Symptom Possible cause Solution Ì The control is not lit and there The input voltage is incorrect Check the main supply voltage. It is no alarm condition.

  • Page 95: Tic Control Alarm Conditions

    T I C C o n t r o l A l a r m C o n d i t i o n s Look here when the Alarm/Shutdown light on the control panel is lit. See Answering an Alarm, in the Troubleshooting section before going to these tables. Alarm Possible cause Solution...
  • Page 96 There is a refrigerant leak. Check for oil in chiller cabinet and bub- bles in refrigerant site glass. Consult Conair Service for repair. The pressure switch is faulty. See Checking Pressure Switches, in the Troubleshooting section.
  • Page 97 T I C C o n t r o l A l a r m C o n d i t i o n s ( c o n t i n u e d ) Alarm Possible cause Solution High Discharge Pressure Clogged/dirty air-cooled condenser.
  • Page 98 T I C C o n t r o l A l a r m C o n d i t i o n s ( c o n t i n u e d ) Alarm Possible cause Solution High Discharge Pressure, Valves were removed.
  • Page 99 T I C C o n t r o l A l a r m C o n d i t i o n s ( c o n t i n u e d ) Alarm Possible cause Solution Sensor Failure SF2 The process temperature sensor failed Check with OHM meter and see if the...
  • Page 100 T I C C o n t r o l A l a r m C o n d i t i o n s ( c o n t i n u e d ) Alarm Possible cause Solution High Temperature Safety The hot gas bypass valve is not work- Have a certified refrigeration technician...
  • Page 101 T I C C o n t r o l A l a r m C o n d i t i o n s ( c o n t i n u e d ) Alarm Possible cause Solution Flow fault (pump and com- The optional To Process and/or From Open valve(s).
  • Page 102 T I C C o n t r o l A l a r m C o n d i t i o n s ( c o n t i n u e d ) Alarm Possible cause Solution Low Temperature Alarm (tAL) Insufficient load for the chiller The chiller needs to be loaded by at least...
  • Page 103 T I C C o n t r o l A l a r m C o n d i t i o n s ( c o n t i n u e d ) Alarm Possible cause Solution Pump Overload (pump and Overload set incorrectly.

  • Page 104: Plc Control Answering Alarms

    P L C C o n t r o l A n s w e r i n g A l a r m s When an alarm condition occurs, the Alarm light on the control panel lights and the control screen displays the alarm message. Low Suction Pressure Before an alarm can be reset using the “Alarm Silence/Reset”...

  • Page 105: Plc Control Alarm Conditions

    P L C C o n t r o l A l a r m C o n d i t i o n s Before an alarm can be reset with the acknowledge key, the alarm condition must be cleared. To acknowledge an alarm is press and hold the alarm silence (#9) but- ton for 3 seconds.
  • Page 106 P L C C o n t r o l A l a r m C o n d i t i o n s C o n t i n u e d If refrigerant discharge pressure (PT-2) goes above 290 psig (for water-cooled High Discharge Pressure models) or 350 psig (for air-cooled models) the compressor shuts down.
  • Page 107 P L C C o n t r o l A l a r m C o n d i t i o n s C o n t i n u e d The 7.5 HP and larger compressors have a High Temperature Protector Module to protect the compressor from high internal temperatures, overcurrent conditions and Compressor Fault phase imbalance.

  • Page 108: Plc Control Alarm Errors

    P L C C o n t r o l A l a r m E r r o r s Alarm Message Description There is low process fluid flow at the pump discharge. Flow Fault The refrigerant pressure, measured at the inlet of compressor 1, is low. Low Suction Pressure The refrigerant pressure, measured at the outlet of compressor 1, is high.

  • Page 109: Plc Control Alarm History Screens

    P L C C o n t r o l A l a r m H i s t o r y S c r e e n s The alarm history screens display the last 10 alarms that have occurred. They are listed in the order of newest to oldest.

  • Page 110: Plc Control Alarm Screen Legend

    P L C C o n t r o l A l a r m S c r e e n L e g e n d Alarm Path Legend Hi Dis Press-Comp2 (listed by priority) Pressure Temperature Default Dual Compressor Alarms 2 through 9 Alarm Hi Dis Press-Comp2...
  • Page 111 PLC; reconnect or replace as needed. Ì Check the PLC indicator lights: Power and Program Run lights should be lit. Contact Conair Service if status is not normal. There is a problem with the control The control panel may have failed. panel.
  • Page 112 P L C C o n t r o l P r o b l e m s C o n t i n u e d Symptom Possible cause Solution The control is lit and there is The input voltage is incorrect Check the main supply voltage.
  • Page 113 P L C C o n t r o l A l a r m P r o b l e m s Alarm Possible cause Solution Flow Fault alarm The optional To Process and From Open valve(s). Process valves are closed. Piping has no Flow Potential Verify that flow is evident for applica- tion.
  • Page 114 P L C C o n t r o l A l a r m C o n d i t i o n s Alarm Possible cause Solution Flow Fault alarm (cont’d.) The evaporator is fouled. Clean Evaporator. See Cleaning the Evaporator or Water-cooled Condenser, in the Maintenance section.
  • Page 115 Refrigerant leak. Check for oil in chiller cabinet and bub- bles in refrigerant sight glass. Consult Conair Service for repair. Faulty pressure transducer. See Checking the Pressure Transducer, in the Troubleshooting section or appendix. Condenser air or water too cold.
  • Page 116 P L C C o n t r o l A l a r m C o n d i t i o n s Alarm Possible cause Solution High Discharge Pressure alarm Clean the filter or coil. See Cleaning the Clogged/dirty air-cooled condenser or Air-cooled Condenser, in the Maintenance filter.
  • Page 117 P L C C o n t r o l A l a r m C o n d i t i o n s Alarm Possible cause Solution Comp Fault alarm Compressor is wired incorrectly. Shut off chiller supply voltage. Switch any two leads: •...
  • Page 118 P L C C o n t r o l A l a r m C o n d i t i o n s Alarm Possible cause Solution Process Pump Overload alarm Motor starter protector (MSP) set Check data tag in Electrical Cabinet. incorrectly.
  • Page 119 P L C C o n t r o l A l a r m C o n d i t i o n s Alarm Possible cause Solution High Temperature The hot gas bypass valve is not work- Have a certified refrigeration technician Safety Temp>95F alarm ing properly (possibly stuck open) replace the solenoid valve.
  • Page 120 P L C C o n t r o l A l a r m C o n d i t i o n s Alarm Possible cause Solution Low Temperature Cutout Insufficient load for the Chiller. The Chiller needs to be loaded by at alarm least 25% of the Chiller capacity for cor- rect operation, adjust as necessary.
  • Page 121 P L C C o n t r o l A l a r m C o n d i t i o n s Alarm Possible cause Solution MSP set incorrectly. Compressor Overload alarm or Check table on wiring diagram for cor- Compressor 2 Overload alarm rect rated load amperage (RLA) draw.
  • Page 122 P L C C o n t r o l A l a r m C o n d i t i o n s Alarm Possible cause Solution High Temperature (T>75°F for Load too high for chiller. Reduce load on chiller; if not able to 5 minutes) alarm.
  • Page 123 P L C C o n t r o l A l a r m C o n d i t i o n s Alarm Possible cause Solution Fan Overload alarm Fan Access door is open. This will cause too much air flow. Close access door.
  • Page 124 P L C C o n t r o l A l a r m C o n d i t i o n s Alarm Possible cause Solution Discharge Pressure Sensor Wiring bad. Check wiring; correct as needed. Failure alarm There is RF interference.
  • Page 125 C h e c k i n g a n d R e p l a c i n g S w i t c h e s WARNING: Electrical hazard Before performing any work on this unit, disconnect and lock out electri- cal power sources to prevent injury from unexpected energization or startup.
  • Page 126 R e p l a c i n g t h e RT D P L C O n l y NOTE: These connections To replace the RTD: may vary depending on the model you have purchased. Disconnect and lockout power to the chiller. Be sure to see the labeling on your particular unit.
  • Page 127 R e m o v i n g P u m p C o m p o n e n t s The pump’s wet end (impeller, motor, and seal assembly) can be removed for service. Disconnect and lockout power to chiller. Open the drain/fill valve and drain the water from the chiller.
  • Page 128 R e p l a c i n g F u s e s WARNING: Electrical hazard Before performing any work on this unit, disconnect and lock out electri- cal power sources to prevent injury from unexpected energization or startup. Always refer to the wiring diagrams that came with your chiller to locate specific electrical components.
  • Page 129 R e p l a c i n g t h e C o n t a c t o r WARNING: Electrical hazard Before performing any work on this unit, disconnect and lock out electrical power sources to prevent injury from unexpected energization or startup. NOTE: Always refer to the wiring diagrams that came with your chiller to locate...
  • Page 131 We ’ r e H e r e t o H e l p Conair has made the largest investment in customer support in the plastics industry. Our service experts are available to help with any problem you might have installing and oper- ating your equipment.
  • Page 132 (except for parts that are typically replaced after normal usage, such as filters, liner plates, etc.). Conair’s guarantee is limited to replacing, at our option, the part or parts determined by us to be defective after examination. The customer assumes the cost of transportation of the part or parts to and from the factory.
  • Page 133 M a i n t e n a n c e L o g Reading Date Maintenance Item Compressor 1 Amps, 100% loaded Compressor 2 Amps, 100% loaded Discharge Pressure 1 Discharge Pressure 2 Suction pressure 1 Suction pressure 2 Evaporator water out/inlet temperature Process Water Pressure...
  • Page 135 E va p o r a t o r a n d P i p i n g P r e s s u r e D r o p s Size 1 PCA/PCW-7.5 PCA/PCW-10, PCA-13 PCA/PCW-5 PCA/PCW-3 PCW-15 PCA/PCW-1.5 Flow Rate, GPM Size 2 PCA/PCW-5 PCA/PCW-20 PCA/PCW-10 PCA/PCW-7.5 PCA/PCW-15 PCA/PCW-25 &...
  • Page 136 P r e s s u r e Ta b l e s C o n d e n s e r a n d P i p i n g P r e s s u r e D r o p s Size 1 PCW-1.5 PCW-7.5 PCW-3...
  • Page 137 O v e r h e a d P l u m b i n g D e t a i l s Overhead piping installations above process connections require installing a check valve in the To Process line and a 12 inch {305 mm} riser with check valve and vacu- um break in the From Process line to prevent siphoning when shutting down.

This manual is also suitable for:

Pcw-30Pca1.5Pca-30

Table of Contents