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Conair VL Series User Manual

Portable chillers air-cooled and water-cooled with capacities from 2 to 40 tons vl series;
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Installation
Maintenance
Operation
Troubleshooting
WARNING - Reliance on this Manual Could Result in Severe Bodily Injury or Death!
This manual is out-of-date and is provided only for its technical information, data and capacities. Portions of this manual
detailing procedures or precautions in the operation, inspection, maintenance and repair of the product forming the subject
matter of this manual may be inadequate, inaccurate, and/or incomplete and cannot be used, followed, or relied upon.
Contact Conair at info@conairgroup.com or 1-800-654-6661 for more current information, warnings, and materials about
more recent product manuals containing warnings, information, precautions, and procedures that may be more adequate
than those contained in this out-of-date manual.
Portable Chillers
VL Series Air-Cooled and Water-Cooled
with Capacities from 2 to 40 tons
The Conair Group, Inc.
One Conair Drive
Pittsburgh, PA 15202
Phone: (412) 312-6000
Fax: (412)-312-6227
UGH021/0301

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Summary of Contents for Conair VL Series

  • Page 1 Contact Conair at info@conairgroup.com or 1-800-654-6661 for more current information, warnings, and materials about more recent product manuals containing warnings, information, precautions, and procedures that may be more adequate...
  • Page 2 UGH021/0301 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 dam- ages 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

    Warranty service procedure Periodic preventative maintenance Special maintenance Solenoid valve service Pump seal service Checking the refrigerant charge Proper cleaning procedure for brazed plate evaporators COMPONENTS Water system Refrigeration system UGH021/0301 VL Series Portable Chillers, 2 to 40 Tons Page: 3...
  • Page 4 Chiller capacity and derate chart Pressure-temperature chart for R-22 refrigerant 8.10 Engineering formulas 8.11 Spare parts list- water-cooled models 8.12 Spare parts list- air-cooled models Service Information Warranty information UGH021/0301 VL Series Portable Chillers, 2 to 40 Tons Page: 4...

  • Page 5: General

    GENERAL INTRODUCTION UNIT LOCATION FOR AIR COOLED MODELS UNIT LOCATION FOR WATER COOLED MODELS EFFICIENCY SAFETY CLEAN AIR ACT MISCELLANEOUS UGH021/0301 VL Series Portable Chillers, 2 to 40 Tons Page: 5...
  • Page 6 When calling for assistance from the Conair Service Department, it is important to know the model and serial number of the particular unit. The model number encodes critical unit information which is helpful in any attempt to troubleshoot operating difficulties.

  • Page 7: Safety

    2 of this manual. If the operator has any questions concerning the location and operation of the ‘VL’ series portable chiller, contact the Conair Service Department at 800-458-1960 or 814-437-6861. UGH021/0301...
  • Page 8 VLW-10 pictured Electrical Liquid Line Condenser Return Cabinet Solenoid Condenser Compressor & Condenser Hot Gas Bypass Valve Centrifugal Condenser Supply Pump Condenser & Caster Filter-Drier (not visible in photograph) VL Series Portable Chillers, 2 to 40 Tons UGH021/0301 Page: 8...

  • Page 9: Installation

    INSTALLATION GENERAL TO AND FROM PROCESS CONNECTIONS WATER SUPPLY CONNECTION AIR COOLED CONDENSER WATER COOLED CONDENSER CONNECTION ELECTRICAL CONNECTION UGH021/0301 VL Series Portable Chillers, 2 to 40 Tons Page: 9...
  • Page 10 Condenser water out connection: connect to tower or city water return Condenser water in connection: connect to tower or city water supply Typical process connections Figure 2.2A for water cooled chiller VL Series Portable Chillers, 2 to 40 Tons UGH021/0301 Page: 10...
  • Page 11 60°F may result in below normal condensing pressures and poor condensing. In such cases, a low-ambient damper assembly is required. Check with the Conair service department for more information on operating with ambients air temperatures above 95°F or below 60°F.
  • Page 12 1/4" copper line connection Liquid receiver condenser intake air (located inside chiller on base) temperature will be Angle valve and cap less than 60°F. See figure 2.4D to the right. Figure 2.4D VL Series Portable Chillers, 2 to 40 Tons UGH021/0301 Page: 12...
  • Page 13 WARNING: Do not connect the unit to a voltage supply not equal to the unit’s voltage requirements as specified on the unit’s data plate. Use of incorrect voltage will void the unit’s warranty and UGH021/0301 VL Series Portable Chillers, 2 to 40 Tons Page: 13...
  • Page 14 Make certain all ground connections to the unit are properly affixed. Make certain power conductor, disconnecting means, and fusing are properly sized according to the unit’s power supply requirements. VL Series Portable Chillers, 2 to 40 Tons UGH021/0301 Page: 14...
  • Page 15 OUT OPEN BACK OF UNIT Figure 2.6A Refrigerant Low Refrigerant High Transformer Fuse Block Power Entry Pressurestat Pressurestat Cabinet Door Freezestat Motor Starter Overload Relay Compressor Starter Figure 2.6B Typical electrical cabinet detail. UGH021/0301 VL Series Portable Chillers, 2 to 40 Tons Page: 15...
  • Page 16 THIS PAGE INTENTIONALLY BLANK VL Series Portable Chillers, 2 to 40 Tons UGH021/0301 Page: 16...

  • Page 17: Operations

    OPERATIONS GENERAL START UP/OPERATIONS PROCEDURE INSTRUMENT/OPERATION SHUT DOWN PROCEDURE UGH021/0301 VL Series Portable Chillers, 2 to 40 Tons Page: 17...
  • Page 18 START UP/OPERATION PROCEDURE SYSTEM FILL The VL series portable chiller has an internal reservoir which must be filled and maintained for proper operation. All VL series chillers have a level switch mounted at the proper water level in the reservoir.
  • Page 19 The motor shaft can be seen through the vent slots in the motor housing or by removing the shaft cover (figure 3.2C). UGH021/0301 VL Series Portable Chillers, 2 to 40 Tons Page: 19...
  • Page 20 Note: reversing any two power leads of the power cord will correctly phase an incorrectly phased VL Series Portable Chillers, 2 to 40 Tons UGH021/0301 Page: 20...
  • Page 21 Figure 3.2D illustrates a typical bypass loop. 21 GPM 5 GPM BYPASS THROTTLING CHILLER PROCESS VALVE - 16 GPM 21 GPM 5 GPM Figure 3.2D Typical low flow by-pass loop UGH021/0301 VL Series Portable Chillers, 2 to 40 Tons Page: 21...
  • Page 22 3.2F). The full load amp rating for the motor is listed on the name plate. Engage the electrical power supply and start the motor by switching ‘on’ the CHILLER ON rocker switch. VL Series Portable Chillers, 2 to 40 Tons UGH021/0301 Page: 22...
  • Page 23 After a short delay, the instrument will display the software version number. At this time, the operator can verify that all lights and digits are functioning properly. If the operator UGH021/0301 VL Series Portable Chillers, 2 to 40 Tons Page: 23...
  • Page 24 TO PROCESS temperature state after twenty seconds of inactivity. The operator can stop operations by switching ‘off’ the CHILLER ON rocker switch. This will disengage the refrigerant and coolant circuits. VL Series Portable Chillers, 2 to 40 Tons UGH021/0301 Page: 24...
  • Page 25 Even with the CHILLER ON rocker switch on, the PUMP light will not illuminate if a safety fault condition exists. COMPRESSOR: illuminates when the instrument engages UGH021/0301 VL Series Portable Chillers, 2 to 40 Tons Page: 25...
  • Page 26 Maintain electrical power to the unit at all times except for service purposes. If the unit is to be disconnected from the process, disengage the voltage supply before removing power cord and process lines. VL Series Portable Chillers, 2 to 40 Tons UGH021/0301 Page: 26...

  • Page 27: Troubleshooting

    TROUBLESHOOTING SENSORS PROCESS PUMP COMPRESSOR BLOWER/FAN LOW FLOW HIGH PRESSURE LOW PRESSURE FREEZESTAT OIL PRESSURE 4.10 CRANKCASE HEATER 4.11 ELECTRONICS UGH021/0301 VL Series Portable Chillers, 2 to 40 Tons Page: 27...
  • Page 28 In some process conditions the minimum flow required cannot be maintained making it necessary to install a bypass line between the to and from process lines. VL Series Portable Chillers, 2 to 40 Tons UGH021/0301 Page: 28...
  • Page 29 The switch will automatically reset when the pressure rises above the cut-in pressure. If this does not occur contact the Conair service department for instructions. The low pressure switch is set to cut-out at 58 psi and cut-in at 63 psi.

  • Page 30: Electronics

    The Display/CPU is used for all normal set ups, diagnostics, temperature readout and operational information. This is not normally a field repairable part. It is designed to be easily removed and replaced if a problem arises. VL Series Portable Chillers, 2 to 40 Tons UGH021/0301 Page: 30...

  • Page 31: Maintenance

    MAINTENANCE WARRANTY SERVICE PROCEDURE PERIODIC PREVENTATIVE MAINTENANCE SPECIAL MAINTENANCE SOLENOID VALVE SERVICE PUMP SEAL SERVICE CHECKING THE REFRIGERANT CHARGE PROPER CLEANING PROCEDURE FOR BRAZED PLATE EVAPORATOR UGH021/0301 VL Series Portable Chillers, 2 to 40 Tons Page: 31...
  • Page 32 “on-site” inspection of the unit in order to determine the course of repair. If the chiller is not covered by the warranty, Conair will advise on the repair and recommend available service contractors. Conair manufactures a complete line of heat transfer equipment. It is of the utmost importance that Conair have the correct model number and serial number of the machine in question.
  • Page 33 Addition of refrigerant. Repair of a refrigerant leak. Adjustment of super heat. Changing of filter-drier or drier core. Repair of a refrigeration solenoid. Valve plate replacement on compressor. (Semi-hermetic compressors only) UGH021/0301 VL Series Portable Chillers, 2 to 40 Tons Page: 33...
  • Page 34 (figure 5.4C). Retaining screw Identify the diaphragm assembly. Gently remove the assembly from the valve body (figure 5.4D). Identify the mesh screen. Gently removed the mesh Coil Figure 5.4B VL Series Portable Chillers, 2 to 40 Tons UGH021/0301 Page: 34...
  • Page 35 Open the water supply to circulate water to the Enclosure tube make-up system. Check the Top bonnet solenoid valve for leakage. Restart the unit as outlined in section 3. Spring Plunger Figure 5.4F UGH021/0301 VL Series Portable Chillers, 2 to 40 Tons Page: 35...
  • Page 36 The operator should “map” the wire terminal locations to ensure correct rewiring. The power cord should be removed from the motor housing (figure 5.5C). Pump motor power cord Figure 5.5C VL Series Portable Chillers, 2 to 40 Tons UGH021/0301 Page: 36...
  • Page 37 Clean motor shaft and lubricate with a mild soap solution. Install new stationary seal Typical impeller member in the pump Figure 5.5G casing cavity (figure 5.5I). UGH021/0301 VL Series Portable Chillers, 2 to 40 Tons Page: 37...
  • Page 38 Restore all cover panels as were removed. When the pump seal replacement procedure is complete, the operator should check for leaks before restarting the unit according the section 3. Seal members Figure 5.5K VL Series Portable Chillers, 2 to 40 Tons UGH021/0301 Page: 38...
  • Page 39 CHECKING THE REFRIGERANT CHARGE All standard Conair chillers are manufactured with thermostatic expansion valves as the metering device to the evaporator. All Conair chillers have a refrigerant sight glass with a moisture indicator. To check the refrigerant charge under normal operating conditions: Remove the plastic cap covering the sight glass, if installed.

  • Page 40: Proper Cleaning Procedure For Brazed Plate Evaporators

    If this possibility exists, Conair recommends filters or strainers be added to the “from process” line. If the evaporator becomes fouled there are a couple of methods for cleaning.
  • Page 41 Restart the unit and check for proper operation. Note: this procedure is not normal maintenance. Maintaining proper water quality and filtration will minimize the need to backflush the evaporator. UGH021/0301 VL Series Portable Chillers, 2 to 40 Tons Page: 41...
  • Page 42 THIS PAGE INTENTIONALLY BLANK VL Series Portable Chillers, 2 to 40 Tons UGH021/0301 Page: 42...

  • Page 43: Components

    COMPONENTS WATER SYSTEM REFRIGERATION SYSTEM UGH021/0301 VL Series Portable Chillers, 2 to 40 Tons Page: 43...
  • Page 44 “condense” into a liquid state still under high pressure. Air flow across the condenser is achieved via a motor driven fan assembly or centrifugal blower (figure 6.2B2). Regulator Tube/shell Figure 6.2B1 valve condenser VL Series Portable Chillers, 2 to 40 Tons UGH021/0301 Page: 44...
  • Page 45 Typical refrigerant sight glass Figure 6.2E reducing the capacity by 50% when the process fluid temperature nears the setpoint (figure 6.2H). UGH021/0301 VL Series Portable Chillers, 2 to 40 Tons Page: 45...
  • Page 46 ‘off ’ cycles. (Semi-hermetic only) Typical hot gas bypass valve Figure 6.2H Oil pressure safety switch: protects the compressor from lubrication failure. (Semi-hermetic only) High pressurestat Figure 6.2I Low pressurestat VL Series Portable Chillers, 2 to 40 Tons UGH021/0301 Page: 46...

  • Page 47: Related Drawings

    DUCT SCHEMATIC FOR AIR COOLED CHILLERS VLA-5A/7.5/10 ELECTRICAL VLA-15/20/25/30 ELECTRICAL VLW-5/7.5/10 MECHANICAL SCHEMATIC 7.10 VLW-15/20/25/30 MECHANICAL SCHEMATIC 7.11 VLW-5/7.5/10 PHYSICAL 7.12 VLW-15/20/25/30/40 PHYSICAL 7.13 VLW-5/7.5/10 ELECTRICAL 7.14 VLW-15/20/25/30 ELECTRICAL UGH021/0301 VL Series Portable Chillers, 2 to 40 Tons Page: 47...
  • Page 48 VLA-5/7.5/10 MECHANICAL SCHEMATIC VL Series Portable Chillers, 2 to 40 Tons UGH021/0301 Page: 48...
  • Page 49 VLA-15/20/25/30 MECHANICAL SCHEMATIC UGH021/0301 VL Series Portable Chillers, 2 to 40 Tons Page: 49...

  • Page 50: Vla-5 Physical

    VLA-5 PHYSICAL 3" 51" 6" 38" 34" VL Series Portable Chillers, 2 to 40 Tons UGH021/0301 Page: 50...

  • Page 51: Vla-7.5/10 Physical

    VLA-7.5/10 PHYSICAL 3" 51" 6" 54" 34" UGH021/0301 VL Series Portable Chillers, 2 to 40 Tons Page: 51...

  • Page 52: Vla-15/20/25/30 Physical

    VLA-15/20/25/30 PHYSICAL 2" 94" 6" 67 1/2" 58" VL Series Portable Chillers, 2 to 40 Tons UGH021/0301 Page: 52...

  • Page 53: Duct Schematic For Air Cooled Chillers

    Butterfly with counterbalance Separate duct support from roof Gate control for exhaust air flow Manual chain control Duct to plant heating system Mating collar Chiller air exhaust port Air cooled chiller UGH021/0301 VL Series Portable Chillers, 2 to 40 Tons Page: 53...

  • Page 54: Vla-5/7.5/10 Electrical

    VLA-5/7.5/10 ELECTRICAL This electrical drawing is presented for illustration purposes only. For exact details, consult the electrical drawing supplied with your machine. VL Series Portable Chillers, 2 to 40 Tons UGH021/0301 Page: 54...

  • Page 55: Vla-15/20/25/30 Electrical

    VLA-15/20/25/30 ELECTRICAL This electrical drawing is presented for illustration purposes only. For exact details, consult the electrical drawing supplied with your machine. UGH021/0301 VL Series Portable Chillers, 2 to 40 Tons Page: 55...

  • Page 56: Vlw-5/7.5/10 Ton Mechanical Schematic

    VLW-5/7.5/10 TON MECHANICAL SCHEMATIC VL Series Portable Chillers, 2 to 40 Tons UGH021/0301 Page: 56...

  • Page 57: Vlw-15/20/25/30 Ton Mechanical Schematic

    7.10 VLW-15/20/25/30 TON MECHANICAL SCHEMATIC UGH021/0301 VL Series Portable Chillers, 2 to 40 Tons Page: 57...
  • Page 58 7.11 VLW 5/7.5/10 TON PHYSICAL 34" 4" 38" 32" VL Series Portable Chillers, 2 to 40 Tons UGH021/0301 Page: 58...

  • Page 59: Vlw-15/20/25/30 Ton Physical

    7.12 VLW 15/20/25/30 TON PHYSICAL 51" 6" 54" 34" UGH021/0301 VL Series Portable Chillers, 2 to 40 Tons Page: 59...

  • Page 60: Vlw 5/7.5/10 Ton Electrical

    7.13 VLW 5/7.5/10 TON ELECTRICAL VL Series Portable Chillers, 2 to 40 Tons UGH021/0301 Page: 60...

  • Page 61: Vlw 15/20/25/30 Ton Electrical

    7.14 VLW 15/20/25/30 TON ELECTRICAL UGH021/0301 VL Series Portable Chillers, 2 to 40 Tons Page: 61...
  • Page 62 THIS PAGE INTENTIONALLY BLANK VL Series Portable Chillers, 2 to 40 Tons UGH021/0301 Page: 62...

  • Page 63: Appendix

    OVERHEAD PIPING KIT PRESSURE - TEMPERATURE CHART FOR R-22 REFRIGERANT 8.10 ENGINEERING FORMULAS 8.11 SPARE PARTS LIST - WATER COOLED MODELS 8.12 SPARE PARTS LIST - AIR COOLED MODELS UGH021/0301 VL Series Portable Chillers, 2 to 40 Tons Page: 63...
  • Page 64 ** Standard voltage is 208-230V/3 phase/60Hz. All others are optional. No allowance for inrush. Service disconnect by owner. Full load amps must be used to size disconnects and supply conductors. Specifications can change at any time. Contact your Conair representative for the most current information. VL Series Portable Chillers, 2 to 40 Tons...
  • Page 65 1900 {862} 2100 {953} 2200 {998} 2500 {1134} Voltages running/full load amps § full full full full full full full full 230V/3 phase/60hz 460V/3 phase/60hz 575V/3 phase/60hz Refrigerant Type HCFC-22 UGH021/0301 VL Series Portable Chillers, 2 to 40 Tons Page: 65...
  • Page 66 WATER SUPPLY The automatic water supply (if equipped) restores the reservoir water level as needed. However, if untreated water is added to an water/glycol solution, dilution will occur VL Series Portable Chillers, 2 to 40 Tons UGH021/0301 Page: 66...
  • Page 67 PRECAUTIONS At any setpoint, the possibility of freezing exists and it is the operator’s responsibility to take necessary action to prevent freezing at all times. UGH021/0301 VL Series Portable Chillers, 2 to 40 Tons Page: 67...
  • Page 68 DOW CHEMICAL 1-800-447-4369 (Canada 1-800-363-6250) Dowfrost inhibited propylene glycol MONSANTO CHEMICAL 1-800-459-2665 Monsanto FS inhibited propylene glycol VL Series Portable Chillers, 2 to 40 Tons UGH021/0301 Page: 68...
  • Page 69 The device pictured is by far the most accurate and easy to use for maintaining and checking for proper glycol levels.reduction in cooling capacity and is virtually impossible to remove. UGH021/0301 VL Series Portable Chillers, 2 to 40 Tons Page: 69...
  • Page 70 21 GPM 5 GPM To assure proper flow on central chillers. Conair installs a low flow safety switch to stop the refrigeration system if the liquid flow falls to approximately 33% of full flow. This is a paddle type flow switch which is mounted directly in the water stream.
  • Page 71 It is recommended that where low flow conditions exist, a bypass system be installed either in the field or by Conair. It is the ultimate responsibility of the user to make sure adequate flow through the evaporator is achieved.
  • Page 72 To prevent tank overflow, an overhead piping kit should be installed. This kit is available from Conair as an option and factory installed, or can be field retrofitted. The overhead piping kit places a solenoid valve on the FROM PROCESS line and a check valve on the TO PROCESS line.
  • Page 73 95°F, chiller derating will occur. For ambients of 95-105°F, select the next larger capacity chiller. For ambients over 105°F, consult factory. * These ranges require special options. UGH021/0301 VL Series Portable Chillers, 2 to 40 Tons Page: 73...
  • Page 74 BROUGHT INTO A ROOM WHERE IT IS 80°, IT MAY TAKE A COUPLE OF HOURS FOR THE UNIT TO WARM UP AND THE PRESSURE TO RISE TO THE SURROUNDING AMBIENT CONDITIONS. VL Series Portable Chillers, 2 to 40 Tons UGH021/0301...
  • Page 75 1 1/2" = 40 GPM 8" = 1,000 GPM 2" = 70 GPM 1 Kilogram Lbs X .454 1 Square Centimeter .155 square inch 1 Square Inch 6.452 sqaure centimeter UGH021/0301 VL Series Portable Chillers, 2 to 40 Tons Page: 75...
  • Page 76 7558000 Low pressure safety P70AB-2 7558500 High pressure safety P70DA-1 8067600 Terminal block PWR DIST #1423570 8244000 Transformer 9T58B43 8837515 Bypass valve 2P072 ” 8990000 Relief valve 400 PSI VL Series Portable Chillers, 2 to 40 Tons UGH021/0301 Page: 76...
  • Page 77 7558000 Low pressure safety P70AB-2 7558500 High pressure safety P70DA-1 8067600 Terminal block PWR DIST #1423570 8244000 Transformer 9T58B43 8837515 Bypass valve 2P072 ” 8990000 Relief valve 400 PSI UGH021/0301 VL Series Portable Chillers, 2 to 40 Tons Page: 77...
  • Page 78 THIS PAGE INTENTIONALLY BLANK VL Series Portable Chillers, 2 to 40 Tons UGH021/0301 Page: 78...
  • Page 79 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 operating your equipment. Your Conair sales representative also can help analyze the nature of your problem, assuring that it did not result from misapplication or improper use.
  • Page 80 Returns must be prepaid. Purchaser must notify Conair in writing of any claim and pro- vide a customer receipt and other evidence that a claim is being made.

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