Chapters
Table of Contents
Related Manuals for Conair EARTHSMART ECM Series
Summary of Contents for Conair EARTHSMART ECM Series
- Page 1 www.conairgroup.com U S E R G U I D E UGH031-0209 EarthSmart ECM Series, 0.50 to 0.75 ton models Corporate Office: 724-584-5500 Instant Access 24/7 (Parts and Service): 800.458.1960 Parts and Service: 814.437.6861...
- 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.
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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 Stopping the chiller ........4-4 Changing temperature units .
- Page 5 A p p e n d i x Safety adjustments ........B-1 A p p e n d i x Water quality control .
- Page 6 l Ta b l e o f C o n t e n t s...
- 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 .
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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 the EarthSmart ECM Series Chiller 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.
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Page 11: Attention: Read This So No One Gets Hurt
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 ( c o n t i n u e d ) CA U T I O N : H o t S u r fa c e s Always protect yourself from hot surfaces when working on the chiller, especially when working on or around the compressor and... - Page 12 1 - 6 l I n t r o d u c t i o n...
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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 E a r t h S m a r t E C M S e r i e s 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 Earthsmart Ecm Series Chiller
W h a t i s t h e E a r t h S m a r t E C M S e r i e s C h i l l e r ? NOTE: Chiller’s environment The Conair EarthSmart ECM Series Chillers provide self-contained sources of and cooling temperatures chilled water and are available with compressor ranges of 0.5 Hp or 0.75 Hp below the default cooling (nominal capacities of 0.41 tons or 0.70 tons of refrigeration). -
Page 15: Limitations
L i m i t a t i o n s Conair EarthSmart ECM Series Chillers are chosen based on the cooling load, ambient temperature and cooling temperature. Cooling load - Choose a chiller that has 0 - 10% more cooling capacity than the process load to be chilled. -
Page 16: How It Works: Process Circulation
H o w i t Wo r k s : P r o c e s s C i r c u l a t i o n (Left-side as viewed from the control) Hot fluid from the process enters the chiller through the “From Process”... - Page 17 H o w i t Wo r k s : R e f r i g e r a n t C i r c u l a t i o n (Left-side as viewed from the control) (Right-side as viewed from the control) From Process inlet Pump To Process outlet...
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Page 18: Component Listing
H o w i t Wo r k s : C o m p o n e n t L i s t i n g Water system • Motor/Pump assembly - The motor/pump assembly circulates chilled coolant through the process loop. The pump assembly is built with brass to maintain water quality. - Page 19 35 PSI. The low pressure switch protects the chillers from possible damage due to low operating pressure. The low pressure switch is field adjustable for setpoints below 45°F {7.2°C}, contact a Conair representative for more information. IMPORTANT: Altering the High Pressure Switch setting will void any chiller warranty.
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Page 20: S P E C I F I C A T I O N S : E A R T H S M A R T E C M
No allowance for inrush current. Ground fault interruption to be supplied by the customer. Full load amps must be used to size supply conductors. Consult a Conair repre- sentative for 50 Hz operation. Specifications can change at any time. Contact your Conair representative for the most current information. -
Page 21: P U M P C U R V E : E A R T H S M A R T E C M
* Pump curves do not reflect pressure drops due to internal piping. This pump curve is non-overloading using the service factor of the motors. Specifications may change without notice. Check with your Conair representative for the most current information. D e s c r i p t i o n l... - Page 22 2 - 1 0 l D e s c r i p t i o n...
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Page 23: 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 24: Unpacking The Boxes
Units are shipped with the casters attached. CAUTION: Lifting Conair EarthSmart ECM Series 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 chiller’s center of gravity. -
Page 25: Warning 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 26: 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 coolant lines can be connected from the process machine to the chiller and back. -
Page 27: 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 NOTE: The ability of the unit to C o n n e c t i o n s maintain process temperature control depends on the method All process piping materials (such as hoses, rigid piping, valves or filters) used of installation. -
Page 28: 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 manually filled during instal- lation using water as its coolant. For atypical process temperatures below 45°F {7.2°C}, use the table below to determine the percentage (by volume) of glycol needed for the process tempera- ture that is required. -
Page 29: Drain Connection
D r a i n C o n n e c t i o n To drain the chiller for storage or transport: Rotate the chiller’s drain valve counterclockwise. If using chemicals or additives with your process coolant, observe local disposal laws and regulations. From Process inlet Water level gauge Fill/drain port... -
Page 30: Checking The Refrigerant Charge
Under low load conditions, when the Hot-gas Bypass valve is energized, bubbles may be visible in the sight glass. This is normal. If the charge is low and the unit is under warranty, contact Conair service. Otherwise have a local, certified refrigeration technician add R-134A refrigerant to the system. -
Page 31: Connecting The Main Power
C o n n e c t i n g t h e M a i n Po w e r The Conair EarthSmart ECM Chiller uses standard 115 Volt, 60 Hz or 220 Volt, 60Hz single-phase power, depending on model. - Page 32 3 - 1 0 l I n s t a l l a t i o n...
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Page 33: 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 E a r t h S m a r t E C M S e r i e s C h i l l e r : C o n t r o l d e s c r i p t i o n s . -
Page 34: C O N T R O L D E S C R I P T I O N S
E a r t h S m a r t E C M C h i l l e r : C o n t r o l D e s c r i p t i o n s A c t u a l C h i l l e r H o t - G a s A l a r m I n d i c a t i o n... -
Page 35: Starting The Chiller
I n f i n i t y B u t t o n Pressing the “Infinity” button will acknowledge alarms and return the user to the Main screen. S t a r t i n g t h e C h i l l e r To start the chiller: Toggle the power switch to the On or “I”... -
Page 36: Stopping The Chiller
S t o p p i n g t h e C h i l l e r To stop the chiller: Toggle the power switch to the Off or “O” position. Off Position IMPORTANT: Do NOT rapidly cycle the chiller’s power on and off (short cycle). Once the power has been turned off, wait at least three (3) minutes before cycling the chiller’s power back on. -
Page 37: Changing Temperature Units
NOTE: The temperature display will not indicate Fahrenheit or Celsius temperature units. The chiller’s control is set for Fahrenheit tem- perature units as standard from Conair. Return Button Press the “Infinity” button to lock in the selection and return to the Main screen. -
Page 38: Chiller Operation Sequence
C h i l l e r O p e r a t i o n S e q u e n c e The EarthSmart ECM Series Chiller has a unique user interface that controls the process temperature and prevents refrigeration migration during compressor off times. - Page 39 C h i l l e r O p e r a t i o n S e q u e n c e ( c o n t i n u e d ) The condenser fan can energize anytime the toggle switch is in the “On” or “I”...
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Page 40: Resetting The High Pressure Switch Of The Compressor
R e s e t t i n g t h e H i g h P r e s s u r e S w i t c h o f t h e C o m p r e s s o r CAUTION: The compressor can The high refrigeration safety pressure switch shuts off the compressor start immediately when the... -
Page 41: 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 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 ..5 - 2 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 . -
Page 42: 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 Checking process fluid level in the pump tank Check the process fluid level in the water level gauge on the back of the chiller. - Page 43 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 ( c o n t i n u e d ) Monthly Inspecting cooling water treatment system If your chiller uses a cooling water treatment system, maintain proper chemi-...
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Page 44: 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 sources to prevent injury from unexpected energization or startup. - Page 45 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 Minerals and other contaminants produce deposits, scales, slime or algae on the heat transfer surfaces exposed to water.
- Page 46 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 ( c o n t i n u e d ) CAUTION: Hot Surfaces Always protect yourself from hot surfaces when working on the chiller, especially when working on or around the compressor and condenser.
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Page 47: 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 48 Check the air filter. If the filter is blinded or torn, replace the filter. Replacement air filters are Replace the chiller’s side panels and then the top lid by replacing the four (4) available from Conair. retaining bolts. Contact Conair Parts (800) 458 1960 Reapply main power.
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Page 49: 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 the chiller, 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 50: Cleaning The Pump Strainer
C l e a n i n g t h e P u m p S t r a i n e r EarthSmart Chillers use a rotary pump to flow process coolant through their internal piping and to the process. A strainer on the pump may periodically need cleaning, depending upon the quality of the process coolant. - Page 51 Remove the strainer from its housing. Inspect the strainer for holes or blinding, clean or replace as necessary. Replacement strainers are available from Conair. Re-install the strainer and strainer cap. Properly seal all piping with approved Contact Conair Parts Teflon tape or pipe dope.
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Page 52: Checking The Refrigerant Charge And Quality
NOTE: In this diagram, the replaced. chiller’s panels are removed If the charge is low or contaminated and the chiller is under warranty, contact Conair for clarity. service; or have a local, certified refrigeration technician service the system. Sight glass... -
Page 53: 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 54: 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 and maintenance procedures outlined in this User Guide. If you do have a problem, this section will help you determine what caused it and how to fix it. Diagnose causes from the control panel. -
Page 55: A Few Words Of Caution
A Fe w Wo r d s o f C a u t i o n Improper corrective actions can lead to hazardous conditions and should never be attempted to sustain production. WARNING: Only a qualified electrical technician should examine and correct problems that require opening the chiller’s electrical enclosure or using electrical wires to diagnose the cause. -
Page 56: Alarms
A l a r m s If the red alarm LED is illuminated, an alarm is activated. The chiller has automat- ically pumped down because it has detected a serious problem that could damage your process or chiller. Note that the alarm must be acknowledged before the con- trol will resume operation by pressing the “Infinity”... -
Page 57: Troubleshooting
Turn the power toggle switch on the to the “On” or “I” position. control to the “On” or “I” position. Open motor winding. Contact Conair Service. Internal overload has tripped. Auto-resetting. Allow the chiller’s motor to cool and restart the chiller. - Page 58 The actual “To Process” temperature is Lower setpoint temperature value. below the setpoint. Operation section entitled, Starting the Chiller. Damaged or defective start capacitor. Contact Conair Service. Poor water flow. Check pump rotation. Clean the pump strainer. Maintenance section entitled, Cleaning the Pump Strainer.
- Page 59 Installation section entitled, Filling the to glycol foaming. Chiller. See Maintenance section entitled, Low flow through the evaporator. Cleaning the Brazed Plate Evaporator. Contact Conair Service. Faulty pump motor. Clean or replace the strainer. Clogged pump strainer. Maintenance section entitled, Cleaning the Pump Strainer.
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Page 60: Checking Or Replacing The Temperature Sensor
To check with ohm meter, measure the resistance across the RTDs. The Replacement RTDs are resistance should be approximately 110 ohm at room temperature. available from Conair. Appendix F entitled, RTD Resistance Chart. Contact Conair Parts Remove the sensor from its housing using an appropriately-sized wrench. - Page 61 C h e c k i n g o r R e s e t t i n g t h e C i r c u i t B r e a k e r s The EarthSmart ECM Series Chiller uses electrical circuit breaker to protect the chiller from overloads or improper operating conditions.
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Page 62: Appendix
Conair equipment may be ordered through the Customer Conair has made the largest investment in customer support in the plastics indus- Service or Parts Department for a try. Our service experts are available to help with any problem you might have nominal fee. -
Page 63: Equipment Guarantee
(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 64: Appendix
Operating configured properly. Contact Temperature Cut In Cut Out Conair Service. 45°F 40°F 35°F 30°F IMPORTANT: A correct mixture of glycol and water must be used as The low pressure switch serves as the mainline defense against freezing. It process coolant for operation below shuts down the chiller if the coolant temperature ever decreases to its setting. -
Page 65: Appendix
Wa t e r Q u a l i t y C o n t r o l Insufficient or improper water treatment can damage the EarthSmart ECM Chiller. A certified water treatment specialist should be consulted for your particular application. -
Page 66: Appendix
95°F {35°C}, chiller derating will occur. chiller’s control must be configured properly. Contact Standard chiller rating is 50°F {10°C} leaving water. For all other temperature Conair Service. settings, output tonnage is altered as follows: IMPORTANT: A correct mixture of Output... - Page 67 P r e s s u r e - Te m p e r a t u r e C h a r t f o r R - 1 3 4 A R e f r i g e r a n t Refrigerant Pressure (PSIG) Saturated Temperature °F {-19.4°C}...
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Page 68: Appendix
RT D R e s i s t a n c e C h a r t You can use the following chart to determine if you need to replace your RTD. F - 1 l A p p e n d i x... -
Page 69: Overhead Plumbing Details
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 a check valve and vacuum break in the “From Process”... -
Page 70: Appendix
E l e c t r i c a l S c h e m a t i c 10 10 H - 1 l A p p e n d i x... -
Page 71: Control Setup
C o n t r o l S e t u p 1/32 DIN Watlow SD controller Setup Sheet Enter the following parameters Menu Parameter Description Setting Set Up Page Input sensor type up & down for C-F Temperature Units (degrees) 3 seconds S.dec Temperature Decimal Places... -
Page 72: Appendix
P l u m b i n g S c h e m a t i c LEVEL J - 1 l A p p e n d i x...