Subscribe to Our Youtube Channel
Related Manuals for PolyScience DuraChill DCA 500
Summary of Contents for PolyScience DuraChill DCA 500
- Page 1 Operators Manual DuraChill™ DCA 500 and DCW 500 Chillers DCA 750 and DCW 750 Chillers DCA 1000 and DCW 1000 Chillers DCA 1300 and DCW 1300 Chillers DCA 1500 and DCW 1500 Chillers 110-262 Rev. A ECN 1894 9/17/03...
-
Page 2: Table Of Contents
Table of Contents Section 1 – Safety and Warranty Information ..................1-1 Safety......................... 1-1 Warranty........................1-2 Unpacking ........................1-3 Section 2 – Introduction..........................2-1 General Description ....................2-1 Component Identification..................... 2-2 2.2.1 Control System....................2-2 2.2.2 Fluid Circulation System ................... 2-3 2.2.3 Cooling System .................... - Page 3 Section 6 – Routine Maintenance ......................6-1 Recommended Routine Maintenance Schedule............6-1 Routine Maintenance Procedures................6-1 6.2.1 Inline Strainer ....................6-1 6.2.2 Reservoir Coolant Level..................6-2 6.2.3 Coolant Freeze Protection ................6-2 6.2.4 Air Filters (Air-Cooled Chillers only)..............6-2 Section 7 – Troubleshooting ........................7-1 Troubleshooting Guide....................
-
Page 4: Section 1 - Safety And Warranty Information
Section 1 – Safety and Warranty Information Safety It is the user’s responsibility to read and understand all instructions and safety precautions included in this manual prior to installing or operating this equipment. Contact our Customer Service Department with any questions regarding the operation of this chiller or the information contained in this manual. -
Page 5: Warranty
Do not attempt to override the power interlock switch or any other safety features on this equipment. Always remove power from the equipment prior to performing any service or maintenance. Do not move the equipment without first disconnecting power. Make sure the equipment’s main power switch is in the OFF position before connecting or disconnecting power. -
Page 6: Section 2 - Introduction
Section 2 – Introduction General Description The PolyScience DuraChill line of industrial chillers offers exceptional performance, reliability, and operational simplicity. Available in both air and water cooled models, these robust self-contained chillers are engineered to provide accurate temperature control in a wide range of process cooling applications. -
Page 7: 2.2 Component Identification
Low tank level indicator/alarm • Full flow bypass valve • Alternate heat transfer fluids • An application data sheet showing how your chiller is equipped is included with the documentation that accompanied this manual. 2.2 Component Identification Your DuraChill Model 500 or 750 Chiller consists of three basic sub-systems: Control system •... -
Page 8: Fluid Circulation System
Refrigerant Pressure Switches — These switches automatically disconnect power from the condenser system in the event that refrigerant pressure is outside factory set high/low values. The Low Pressure Switch is set to cutout at 15 PSI. The High Pressure Switch is set to cutout at 375 PSI on air-cooled units and at 290 PSI on water-cooled units. -
Page 9: Cooling System
2.2.3 Cooling System The condenser on your Chiller is either air-cooled (DCA 500 and DCA 750) or water-cooled (DCW 500 and DCW 750. In addition, the air-cooling system may be either local or external (optional); water-cooling may use either a coil (standard) or shell and tube (optional) design. The following components are common to all systems. - Page 10 Refrigerant High Temperature Switch — Automatically disconnects power from the condenser system when refrigerant temperature reaches 210° F. Restores power when the refrigerant temperature falls below 160° F. Water-Cooled Condenser (Shell and Tube) Condenser— Water-cooled coils used to cool refrigerant gas. Water flow through these coils should be regulated at 15.4 GPM for DCW 500 Chillers and 22.3 GPM for DCW 750 Chillers.
-
Page 11: Section 3 - Specifications
Section 3 – Specifications Air-Cooled Chillers – DCA 500 and DCA 750 Model DCA 500 DCA 750 Process Temperature 32° to 86° F (0° to 30° C); 5° to 185° F (-15° to 85° C) optional Temperature Stability ±2.0° F (±1.11° C) Ambient Operating Temperature 60°... -
Page 12: Water-Cooled Chillers - Dcw 500 And Dcw 750
Water-Cooled Chillers – DCW 500 and DCW 750 Model DCW 500 DCW 750 Process Temperature 32° to 86° F (0° to 30° C); 5° to 185° F (-15° to 85° C) optional Temperature Stability ±2.0° F (±1.11° C) Ambient Operating Temperature 60°... -
Page 13: Air-Cooled Chillers - Dca 1000, Dca 1300 And Dca 1500
Air-Cooled Chillers – DCA 1000, DCA1300, and DCA 1500 Model DCA 1000 DCA 1300 DCA 1500 Process Temperature 32° to 86° F (0° to 30° C); 5° to 185° F (-15° to 85° C) optional Temperature Stability ±2.0° F (±1.11° C) Ambient Operating 60°... -
Page 14: Water-Cooled Chillers - Dca 1000, Dca 1300 And Dca 1500
Water-Cooled Chillers – DCW 1000, DCW1300, and DCW 1500 Model DCW 1000 DCW 1300 DCW 1500 Process Temperature 32° to 86° F (0° to 30° C); 5° to 185° F (-15° to 85° C) optional Temperature Stability ±2.0° F (±1.11° C) Ambient Operating 60°... -
Page 15: Section 4 - Installation And Startup
Section 4 – Installation and Startup Figure 4-1 Site Requirements 4.1.1 Ambient Temperature and Relative Humidity The DuraChill Chiller is designed for indoor installation in ambient temperatures between 60° and 95° F (16° to 35° C); relative humidity should be between 20% and 80% (non-condensing). 4.1.2 Location The Chiller should be installed on a level surface capable of supporting 1500 pounds (680 kg) or... -
Page 16: Plumbing
Plumbing See Figure 4-1. 4.2.1 Process Piping The Chiller incorporates two 1½ inch female NPT fittings on the rear of the enclosure for the process inlet and outlet connections. It is strongly recommended that shutoff valves be installed on both of these connections. NOTE: Do not connect process piping smaller than 1 inch to the Chiller inlet and outlet. -
Page 17: Signal Inputs/Outputs
Signal Inputs/Outputs See Figure 4-1. All optional signal input/output connections are made on the rear of the Chiller. These connections should be made before connecting electrical power to the Chiller or beginning startup procedures. 4.4.1 Remote On/Off This allows the user to turn the Chiller On and Off using a remote dry contact. The Chiller is On when the contact is open;... -
Page 18: Electrical Power
Electrical Power All electrical connections should be made by a qualified, licensed electrician. Proper building codes and safety regulations should be followed. Make sure that the power supply to the Chiller is the same voltage, frequency, and phase as indicated on the identification label. The Chiller is designed with cutouts on the right side and interior of the enclosure to accommodate the electrical power supply conduit. -
Page 19: Startup
Route the wiring through the side of the Chiller, down to the electrical box, and to the main disconnect. Be sure to connect the wires in the proper phase sequence. I.e., L1,L2, and L3. Provide suitable conduit strain relief and grounding. Once the power connection has been made, the enclosure door closed, and the Power Switch/Disconnect placed in the On position, you are ready for Chiller startup. -
Page 20: Starting Process Fluid Flow
4.6.2 Starting Process Fluid Flow WARNING: The Chiller’s electrical power phase connection should be checked for proper wiring on initial startup. A reversed phase sequence will cause the pump, fan, and compressor to run in reverse, with potentially damaging results. Check for proper pump rotation by looking through the slots on the back of the pump with a flashlight as the pump starts up. -
Page 21: Selecting Celsius Or Fahrenheit
4.6.4 Selecting Celsius or Fahrenheit NOTE: The factory default units of measure is ° C. Press and hold the Set/Menu button until “UNITS” appears on the display. Press Set/Menu again to display the current temperature scale (° C or ° F). Rotate the Setting Adjustment knob until the desired temperature scale is displayed. -
Page 22: Section 5 - Normal Operation
Section 5 – Normal Operation ° C and ° F LEDs Setting Adjustment Temperature Display Knob Set/Menu Key Power Keys Power On When the Power Switch/Disconnect is placed in the On position, the Controller goes into a “standby” mode. Four decimal points (..) will appear on the Controller’s display. IMPORTANT: Do not turn Controller power On until the Chiller reservoir has been filled. -
Page 23: Controller Display / Menu Structure
Controller Display / Menu Structure Display Description When ° F or ° C LED is lit continuously, the actual fluid temperature is being displayed. When the ° F LED is flashing, the set point temperature is being displayed. This menu item provides access to the Temperature Scale. It allows the user to UNITS select the temperature scale used to display all temperature values. -
Page 24: Selecting Celsius Or Fahrenheit (Units)
Selecting Celsius or Fahrenheit (UNITS) Press and hold the Set/Menu button until “UNIT” appears on the display. Press Set/Menu again to display the current temperature scale (° C or ° F). Rotate the Setting Adjustment knob until the desired temperature scale is displayed. Press the Set/Menu button to return to the Operational Setup Menus. -
Page 25: Setting The Down/Up Control Bands (Dcb / Ucb)
Setting the Down/Up Control Bands (dcb / ucb) The Down and Up Control Band values are used to control how frequently the compressor cycles on and off. In general, you should only be concerned with these settings if your process heat load is less than 50%. -
Page 26: Controller Operating, Alarm, And Error Messages
5.11 Controller Operating, Alarm, and Error Messages The following table lists the various messages which may appear on the Controller’s digital display. Some are normal operating displays, others indicate that an alarm condition or malfunction has been detected. See Section 5.2 for information on Menu displays. Display Message Description / Action Required... -
Page 27: Remote Control
5.13 Remote Control Chiller operation can be controlled remotely via the RS232 (RS485 optional) interface. See Section 4.4.2 for installation and protocol information. The following commands may be executed remotely: Power On/Off Change Set Point Read Fluid Temperature Read Temperature Units 5.14 Loss of Power In the event that power is lost while the Chiller is operating, the unit will automatically begin... -
Page 28: Section 6 - Routine Maintenance
Section 6 – Routine Maintenance Recommended Routine Maintenance Schedule Routine Maintenance Frequency Procedure Inspect and clean inline Weekly for the first month of operation; strainer every three months thereafter. Check reservoir coolant level Monthly Check coolant freeze Monthly protection Inspect and clean air filters Weekly for the first month of operation;... -
Page 29: Coolant Freeze Protection
If fluid replacement is required, slowly add coolant to the reservoir until the proper fill level is achieved. 6.2.3 Coolant Freeze Protection Chillers being operated below 15° C (59° F) must be protected with an antifreeze solution (see Section 4.6.1). If this is the case with your Chiller, the coolant should be checked periodically for proper freeze protection. -
Page 30: Section 7 - Troubleshooting
Section 7 – Troubleshooting WARNING: Refer servicing to qualified service personnel. When power is on, dangerous voltages exist within chassis components. Use extreme care when measuring voltages on live circuits. Troubleshooting Guide Symptom Possible Cause Corrective Action(s) ..Controller power OFF Press Controller ON button. -
Page 31: Resetting The High Refrigerant Pressure Safety Cutout
Resetting the High Refrigerant Pressure Safety Cutout An excessive ambient and/or process heat load can cause the Chiller’s high refrigerant pressure safety cutout to activate, removing power from the condenser and (on air-cooled Chillers) fan. The safety is factory-set to activate at a refrigerant pressure of 350 PSI. To reset the high refrigerant pressure safety cutout switch, proceed as follows: Correct the condition causing the excessive head load. -
Page 32: Section 8 - Service And Technical Support
Section 8 – Service and Technical Support If you have followed the troubleshooting steps outlined in Section 7 and your Chiller still fails to operate properly, contact the supplier from whom the unit was purchased. Have the following information available for the customer service person: —... -
Page 33: Appendix
Appendix Flow Schematic... -
Page 34: Electrical Schematic
Electrical Schematic...
Need help?
Do you have a question about the DuraChill DCA 500 and is the answer not in the manual?
Questions and answers