Conair PCW-1.5 User manual

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

Please record your equipment’s
model and serial number(s) and
the date you received it in the
spaces provided.
It’s a good idea to record the model and serial number(s) of your equipment and
the date you received it in the User Guide. Our service department uses this infor-
mation, along with the manual number, to provide help for the specific equipment
you installed.
Please keep this User Guide and all manuals, engineering prints and parts lists
together for documentation of your equipment.
Date:
Manual Number: UGH024-0907
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.
Copyright 2007 l The Conair Group l All rights reserved

Table of Contents
1-1 Introduction
Purpose of the user guide. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
How the guide is organized . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Your responsibilities as a user. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
ATTENTION: Read this so no one gets hurt . . . . . . . . . . . . . . . . . . . 1-4
2-1 Description
What is the Portable Chiller? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2
Typical applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-3
Limitations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
How it works:Water-cooled Portable Chillers. . . . . . . . . . . . . . . . . .2-4
How it works: Air-cooled Portable Chillers. . . . . . . . . . . . . . . . . . . . 2-6
Portable Chiller features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
Pump curves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
3-1 Installation
Unpacking the boxes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Warnings and cautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Preparing for installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Making process plumbing connections . . . . . . . . . . . . . . . . . . . . . . 3-5
Filling the Chiller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Checking refrigerant charge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
Connecting the main power source. . . . . . . . . . . . . . . . . . . . . . . . 3-11
Checking electrical connections . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
TIC CONTROL
Checking pump rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
Table of Contents l i

Checking the compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
Checking the water level gauge . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
PLC CONTROL
Initially warming the Chiller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
Checking the pump for rotation. . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15
Checking for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
Initially starting the Chiller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17
Stopping the Chiller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18
4-1 Operation
TIC control features. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
PLC control features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Before starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
TIC CONTROL
Starting/stopping the Chiller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
Changing settings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
Changing the setpoint temperature. . . . . . . . . . . . . . . . . . . . . . . . . 4-8
Menu features. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
Tuning the Chiller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
PLC CONTROL
Powering up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16
Setup menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17
Running/stopping the Chiller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18
Viewing Chiller run menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18
Changing setpoint temperature. . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21
Changing high temperature deviation . . . . . . . . . . . . . . . . . . . . . . 4-22
Setting percent glycol . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23
Selecting the temperature scale . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25
Resetting PID settings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-26
Setting fan setpoints. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-27
ii l Table of Contents

Setting discharge pressure setpoint . . . . . . . . . . . . . . . . . . . . . . . 4-29
Setting PID values. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-30
Manually starting/stopping the pump . . . . . . . . . . . . . . . . . . . . . . 4-31
5-1 Maintenance
Maintenance features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Warnings and cautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Preventative maintenance schedule . . . . . . . . . . . . . . . . . . . . . . . . 5-4
PLC control entering maintenance screens . . . . . . . . . . . . . . . . . . . 5-6
Checking electrical connections . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
Cleaning the evaporator brazed plate or water-cooled condenser. . 5-8
Cleaning the air-cooled condenser . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
Checking the refrigerant charge . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
Checking the reservoir level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11
PLC control setting auto tune mode . . . . . . . . . . . . . . . . . . . . . . . 5-12
6-1 Troubleshooting
Before beginning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
A few words of caution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Identify the cause of a problem . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
TIC control answering an alarm . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
TIC control problems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
TIC control alarm conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
PLC control answering alarms. . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16
PLC control alarm conditions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-17
PLC control alarm errors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-20
PLC control alarm history screens. . . . . . . . . . . . . . . . . . . . . . . . . 6-21
PLC control alarm screen legend. . . . . . . . . . . . . . . . . . . . . . . . . . 6-22
PLC control control problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-23
Table of Contents l iii

PLC control alarm problems . . . . . . . . . . . . . . . . . . . . . . . . 6-25
Checking and replacing switches . . . . . . . . . . . . . . . . . . . . 6-37
Replacing the RTD. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-38
Removing the pump components . . . . . . . . . . . . . . . . . . . . 6-39
Replacing fuses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-40
Replacing the contractor. . . . . . . . . . . . . . . . . . . . . . . . . . . 6-41
AAppendix
Customer service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1
Maintenance log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1
Pressure tables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-1
Overhead plumbing details . . . . . . . . . . . . . . . . . . . . . . . . . . D-1
iv l Table of Contents

Introduction
Purpose of the user guide. . . . . . . . . . . . . . 1-2
How the guide is organized. . . . . . . . . . . . . 1-2
Your responsibilities as a user. . . . . . . . . . . 1-3
ATTENTION:
Read this so no one gets hurt . . . . . . . . 1-4
SECTION
1
Introduction l 1-1
1
Introduction

✐
Purpose of the User Guide
This User Guide describes Conair’s Portable Chillers and explains step-
by-step how to install, operate, maintain and repair this equipment.
Before installing this product, please take a few moments to read the User
Guide and review the diagrams and safety information in the instruction
packet.You also should review manuals covering associated equipment in
your system. This review won’t take long, and it could save you valuable
installation and operating time later.
How the Guide is Organized
Symbols have been used to help organize the User Guide and call your
attention to important information regarding safe installation and operation.
Symbols within triangles warn of conditions that could be hazardous to users or
could damage equipment. Read and take precautions before proceeding.
Numbers indicate tasks or steps to be performed by the user.
A diamond indicates the equipment’s response to an action performed by the user.
An open box marks items in a checklist.
A circle marks items in a list.
Indicates a tip. A tip is used to provide you with a suggestion that will help you with
the maintenance and the operation of this equipment.
Indicates a note. A note is used to provide additional information about the steps
you are following throughout the manual.
1
◆
❒
•
✒
1-2 l Introduction

Introduction l 1-3
Your Responsibility as a User
You must be familiar with all safety procedures concerning installation, opera-
tion and maintenance of this equipment. Responsible safety procedures include:
•Thorough review of this User Guide, paying particular attention
to hazard warnings, appendices, and related diagrams.
•Thorough review of the equipment itself, with careful attention
to voltage sources, intended use, and warning labels.
•Thorough review of instruction manuals for associated equipment.
•Step-by-step adherence to instructions outlined in this User Guide.
1
Introduction

ATTENTION:
Read this so no one gets hurt
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.
WARNING: Improper installation, operation, or
servicing may result in equipment damage or
personal injury.
This equipment should be installed, adjusted, and serviced by qualified
technical personnel who are familiar with the construction, operation,
and potential hazards of this type of machine.
All wiring, disconnects, and fuses should be installed by qualified elec-
trical technicians in accordance with electrical codes in your region.
Always maintain a safe ground. Do not operate the equipment at
power levels other than what is specified on the machine serial tag and
data plate.
WARNING: Electrical Hazard
Before performing any work on this item, disconnect and lock out elec-
trical power sources to prevent injury from unexpected energization or
startup.
CAUTION: Hot Surfaces
Always protect yourself from hot surfaces when working on the
Portable Chiller, especially when working on or around the compressor
and condenser. These devices can reach up to 160°F {71°C}.Allow
these devices to cool before performing any maintenance or trou-
bleshooting.
1-4 l Introduction