HP Refrigerated Recirculating Chillers User manual

Operators Manual
Refrigerated Recirculating Chillers
Powerful Cooling
Microprocessor Controller
Digital Set & Read with
High Flow Centrifugal Pump,
Positive Displacement Pump or
Turbine Pump
110-116 rev. D
ecn 1390

Section 1 - General Information
1.1 Warranty
1.2 Unpacking
1.3 Package Contents
1.4 Description
1.5 Specifications and Pump Performance
Section 2 - Set Up
2.1 Location
2.2 Reservoir Fluids
2.3 Pump, Hoses and Couplings
2.4 Setting Up a Closed System or Cooling Coil to the Chiller
2.5 Setting Up an Open Bath System to the Chiller
Section 3 - Operation
3.1 Power Requirements
3.2 Temperature Setting and Adjustments
3.3 Selection of Celsius or Fahrenheit
3.4 Setting the Readout High Limit
3.5 Controller Display Messages
3.6 Draining the Unit
3.7 Controller Default Settings
Section 4 - Diagram of Models
Section 5 - Maintenance
5.1 Standard Magnetic Drive Centrifugal Pump Motor
5.2 Positive Displacement High Pressure Pump Motor
5.3 Fluid Filter Included With High Pressure Pump
5.4 Refrigeration Air Vents & Air Filter
Section 6 - Troubleshooting
6.1 Unit Disabled
6.2 No Pumping
6.3 Insufficient Pumping
6.4 No Cooling or Insufficient Cooling
Section 7 - Service and Technical Support
Section 8 - Replacement Parts
2
This symbol marks chapters and sections of
this instruction manual which are particularly
relevant to safety.
When attached to the unit, this symbol draws
attention to the relevant section of the
instruction manual.
This symbol indicates hazardous voltages
may be present.
Table of Contents

Section 1 - General Information
1.1 Warranty
Thank you for your purchase. We are confident it will serve you for a long time. Our warranty to you
is as follows:
The manufacturer agrees to correct for the original user of this product, either by repair, or at the
manufacturer’s election, by replacement, any defect which develops after delivery of this product
within the period as stated on the warranty card. In the event of replacement, the replacement unit
will be warranted for 90 days or warranted for the remainder of the original unit’s parts or labor
warranty period, whichever is longer.
If this product should require service, contact the manufacturer/suppliers’ office for instructions. When
return of the product is necessary, a return authorization number will be assigned and the product
should be shipped, transportation charges pre-paid, to the indicated service center. To insure prompt
handling, the return authorization number should be placed on the outside of the package and a
detailed explanation of the defect enclosed with the item.
This warranty shall not apply if the defect or malfunction was caused by accident, neglect,
unreasonable use, improper service, or other causes not arising out of defects in material or
workmanship. There are no warranties, expressed or implied, including, but not limited to, those of
merchantability or fitness for a particular purpose which extends beyond the description and period
set forth herein. The manufacturer’s sole obligation under this warranty is limited to the repair or
replacement of a defective product and the manufacturer shall not, in any event, be liable for any
incidental or consequential damages of any kind resulting from use or possession of this product.
Some states do not allow: (A) limitations on how long an implied warranty lasts or (B) the exclusion or
limitation of incidental or consequential damages, so the above limitations or exclusions may not
apply to you. This warranty gives you specific legal rights. You may have other rights which vary
from state to state.
1.2 Unpacking
Your recirculating chiller is shipped in a special carton. Retain the carton and all packing materials
until the unit is completely assembled and working properly. Set up and run the unit immediately to
confirm proper operation. Beyond one week, your unit may be warranty repaired, but not replaced. If
the unit is damaged or does not operate properly, contact the transportation company, file a damage
claim, then contact the company where your unit was purchased.
1.3 Package Contents
– Recirculating Chiller
– Operators Manual
– Warranty Card
– 2 sets of Inlet/Outlet Adapters: 1/2 inch I.D. tubing; 5/8 inch I.D. tubing
– Durable Tubing, 1/2 inch I.D.
1.4 Description
These chillers provide cooling power for demanding applications, and economically replace tap water
cooling systems. All models have a microprocessor controller, digital set/read and readout in °C or
°F. The refrigeration system has modulation capability to provide cooling as needed and thus greater
temperature stability and longer compressor life. Wetted parts are brass, copper, polypropylene,
PVC, nylon and stainless steel.
3

4
1.5 Chiller Specifications and Pump Performance
Pump Performance
Comparison of Pump Options
Centrifugal Pump Capacity Positive Displacement Pump Capacity
1/2 HP
1/3 HP
1/4 HP
1 HP
3/4HP
General Specifications To All Chillers
Temperature Setability ± 0.1°C
Temperature Uniformity ± 0.5°C
Readout Selectability °C or °F
Pump Inlet & Outlet 1/2inch NPT

Notes: Refer to the serial number plate on rear of the chiller for model and electrical data.
Cooling Capacity, Watts x 3.41 = BTUs/hr. Performance specifications determined at ambient temperature of 20°C/68°F.
For 50Hz models, derate cooling capacity and pump flow by 17%.
External Pressure Reducing Assembly (for Positive Displacement Pump models) Steps down high outlet pressure to 10 to 45 psi. Cat. No 060302
5
6000 Series Standard Chillers with Magnetic Drive Centrifugal Pump
Model 6205 6305 6505
Operating Temperature -5° to 40°C -5° to 40°C -10° to 40°C
Compressor 1/4 hp 1/3 hp 1/2 hp
Cooling Capacity @ 20°C 750 Watts 1200 Watts 1320 Watts
10°C 450 Watts 825 Watts 1055 Watts
0°C 100 Watts 375 Watts 550 Watts
Pressure at 0 Flow Rate 10 psi 10 psi 10 psi
Flow Rate @ 0 psi 4.3 gpm / 16.3 lpm 4.3 gpm / 16.3 lpm 4.3 gpm / 16.3 lpm
Reservoir Capacity 1.65 gal / 6.25 liters 1.65 gal / 6.25 liters 1.65 gal / 6.25 liters
Dimensions (in.) 24 x 143/8x 261/224 x 143/8x 261/224 x 143/8x 261/2
h x w x d (cm) 61 x 36.5 x 67.3 61 x 36.5 x 67.3 61 x 36.5 x 67.3
Shipping Weight 155 lbs 165 lbs 170 lbs
Volts, Hz, Amps 120V, 60Hz, 6.8A 120V, 60Hz, 8A 120V, 60Hz, 13A
Volts Range 108V to 132V 108V to 132V 108V to 132V
60Hz Cat. No. 080501 080511 080521
Volts, Hz, Amps 240V, 50Hz, 3.4A 240V, 50Hz, 4A 240V, 50Hz, 6.5A
Volts Range 198V to 264V 198V to 264V 198V to 264V
Over Voltage: Category II
50Hz Cat. No. 080506 080516 080526
Additional Specifications for "P" Series 6000 Chillers with Positive Displacement Pump
Model "P" Series 6205P 6305P 6505P
Flow Rate @ 0 psi 1 gpm / 3.8 lpm 1 gpm / 3.8 lpm 1 gpm / 3.8 lpm
Pump Pressure (Adjustable) 20 to 100psi 20 to 100psi 20 to 100psi
Shipping Weight 160 lbs 170 lbs 170 lbs
Volts, Hz, Amps 120V, 60Hz, 9.6A 120V, 60Hz, 10.8A 120V, 60Hz, 15.8A
Volts Range 108V to 132V 108V to 132V 108V to 132V
60Hz Cat. No. 080502 080512 080522
Volts, Hz, Amps 240V, 50Hz, 4.8A 240V, 50Hz, 5.4A 240V, 50Hz, 8A
Volts Range 198V to 264V 198V to 264V 198V to 264V
Over Voltage: Category II
50Hz Cat. No. 080507 080517 080527
Additional Specifications for "T" Series 6000 Chillers with Turbine Pump
Model "T" Series 6205T 6305T 6505T
Flow Rate @ 0 PSI 3.5 gpm / 13.2 lpm 3.5 gpm / 13.2 lpm 3.5 gpm / 13.2 lpm
Pump Pressure (Adjustable) 20 to 100psi 20 to 100psi 20 to 100psi
Volts, Hz, Amps 120V, 60Hz, 9.6A 120V, 60Hz, 10.8A 120V, 60Hz, 15.8A
Volts Range 108V to 132V 108V to 132V 108V to 132V
60Hz Cat. No. 080503 080513 080523
Volts, Hz, Amps 240V, 50Hz, 4.8A 240V, 50Hz, 5.4A 240V, 50Hz, 8A
Volts Range 198V to 264V 198V to 264V 198V to 264V
Over Voltage: Category II
50Hz Cat. No. 080508 080518 080528
Environmental Conditions • Indoor Use Only
• Maximum Altitude : 2000 meter • Operating Ambient : 5° to 30°C
• Relative Humidity : 80% for temperatures to 30°C • Pollution Degree : 2
• Class 1 : Residential, Commercial, Light Industrial • Class 2 : Heavy Industrial

Notes: Refer to the serial number plate on rear of the chiller for model and electrical data.
Cooling Capacity, Watts x 3.41 = BTUs/hr. Performance specifications determined at ambient temperature of 20°C/68°F.
For 50Hz models, derate cooling capacity and pump flow by 17%.
External Pressure Reducing Assembly (for Positive Displacement Pump models) Steps down high outlet pressure to 10 to 45 psi. Cat. No 060302
6
6000 Series Standard Chillers with Magnetic Drive Centrifugal Pump
Model 6705 6105 6155
Operating Temperature -15° to 40°C -15° to 40°C +5° to 35°C
Compressor 3/4 hp 1 hp 11/2 hp
Cooling Capacity @20°C 2500 Watts @20°C 2850 Watts @20°C 5200 Watts
@10°C 1700 Watts @10°C 1925 Watts @10°C 3600 Watts
@ 0°C 760 Watts @ 0°C 940 Watts @ 5°C 2700 Watts
Pressure at 0 Flow Rate 10 psi 10 psi 10 psi
Flow Rate @ 0 psi 4.3gpm / 16.3 lpm 4.3 gpm / 16.3 lpm 4.3 gpm / 16.3 lpm
Reservoir Capacity 1.65 gal / 6.25 liters 1.65 gal / 6.25 liters 6.25 gal / 23.65 liters
Dimensions (in.) 24 x 143/8x 261/224 x 143/8x 261/230 x 21x 27
h x w x d (cm) 61 x 36.5 x 67.3 61 x 36.5 x 67.3 76.2 x 53.3 x 68.6
Shipping Weight 178 lbs 178 lbs 450 lbs
Volts, Hz, Amps 208-230V, 60Hz, 7.5A 208-230V, 60Hz, 8A 208-230V, 60Hz, 12A
Volts Range 187V to 253V 187V to 253V 187V to 253V
60Hz Cat. No. 080531 080542 080593
Volts, Hz, Amps 240V, 50Hz, 7.5A 240V, 50Hz, 8.5A 240V, 50Hz, 12A
Volts Range 198V to 264V 198V to 264V 198V to 264V
Over Voltage: Category II
50Hz Cat. No. 080536 080546 080594
Additional Specifications for "P" Series 6000 Chillers with Positive Displacement Pump
Model "P" Series 6705P 6105P 6155P
Flow Rate @ 0 psi 4 gpm / 15.2 lpm 4 gpm / 15.2 lpm 4 gpm / 15.2 lpm
Pump Pressure (Adjustable) 20 to 100psi 20 to 100psi 20 to 100psi
Shipping Weight 178 lbs 178 lbs 450 lbs
Volts, Hz, Amps 208-230V, 60Hz, 10A 208-230V, 60Hz, 11A 208-230V, 60Hz, 12A
Volts Range 187V to 253V 187V to 253V 187V to 253V
60Hz Cat. No. 080532 080544 080596
Volts, Hz, Amps 240V, 50Hz, 10A 240V, 50Hz, 11A 240V, 50Hz, 12A
Volts Range 198V to 264V 198V to 264V 198V to 264V
Over Voltage: Category II
50Hz Cat. No. 080537 080547 080597
Additional Specifications for "T" Series 6000 Chillers with Turbine Pump
Model "T" Series 6705T 6105T 6155T
Flow Rate @ 0 PSI 3.5 gpm / 13.2 lpm 3.5 gpm / 13.2 lpm 3.5 gpm / 13.2 lpm
Pump Pressure (Adjustable) 20 to 100psi 20 to 100psi 20 to 100psi
Volts, Hz, Amps 208-230V, 60Hz, 9.6A 208-230V, 60Hz, 10.8A 208-230V, 60Hz, 12A
Volts Range 108V to 132V 108V to 132V 187V to 253V
60Hz Cat. No. 080533 080543 080598
Volts, Hz, Amps 240V, 50Hz, 9.6A 240V, 50Hz, 10.8A 240V, 50Hz, 12A
Volts Range 198V to 264V 198V to 264V 198V to 264V
Over Voltage: Category II
50Hz Cat. No. 080538 080548 080599
Environmental Conditions • Indoor Use Only
• Maximum Altitude : 2000 meter • Operating Ambient : 5° to 30°C
• Relative Humidity : 80% for temperatures to 30°C • Pollution Degree : 2
• Class 1 : Residential, Commercial, Light Industrial • Class 2 : Heavy Industrial

Section 2 - Set Up
Before proceeding, be sure all power is off
2.1 Location
Locate the chiller on a strong, level surface. Insure easy access to the top cover and position
the chiller for unobstructed air flow through the front and rear screens. The front wheels can be
locked to keep the chiller in place while in use. Avoid voltage drops by using properly grounded
power outlets wired with 14 gauge or larger diameter wire. If possible, be close to the power
distribution panel. Minimize low line voltage problems by eliminating the use of extension cords.
2.2 Reservoir Fluids
For most applications above +15°C, distilled water is satisfactory. For operation below +15°C, the
chiller MUST be protected with an antifreeze solution. Ethylene glycol (laboratory grade) and water
in a 50/50 mixture is satisfactory from +15°C to -15°C. Select a fluid that is compatible with the
chiller's wetted parts of brass, copper, polypropylene, PVC, nylon and stainless steel. Only use fluids
that will satisfy safety, health and equipment compatibility requirements. CAUSTIC, CORROSIVE
OR FLAMMABLE FLUIDS MUST NEVER BE USED.
Do not use a flammable fluid as a fire hazard may result.
WARNING!
Operation below +15°C requires antifreeze in the circulating fluid.
2.3 Pump, Hoses and Couplings
To maintain a safe workplace and to avoid leaks, special care should be taken when choosing hoses
and connectors for the chiller.
1. Pressure ratings - Hoses should be able to withstand the largest pressure that they will
encounter. For positive displacement pump models, this is 100 psi.
2. Flexible tubing - Avoid tubing that will expand and take up fluid volume when operating at the
desired pressure.
3. Hose diameter - The fittings on the chiller Outlet and Inlet lines are internally threaded,
1/2inch I.D. N.P.T. The 2 adapters sets supplied are for1/2inch I.D. tubing and 5/8inch I.D.
tubing. Other fittings can be used if a smaller hose diameter is desired. Remember that the
operating pressure in the circulating system increases when using a smaller diameter hose.
4. Couplings & Clamps - The use of screw-tightened hose clamps is necessary on all joints to
insure good, tight connections. Quick connectors are not recommended because they have the
potential for restricting flow rate.
7

IMPORTANT!
Chillers equipped with a high pressure positive displacement pump have a pressure
regulator inside of the chiller and a pressure gauge on the control panel. To access this
regulator, remove the rear air grille. The valve is located to the right. On models 6107 & 6705,
6155 the regulator is located center point, upper grille (rear).
The Pressure Valve is FACTORY ADJUSTED to 40psi. If you do NOT want to operate at this
pressure, or do not know what your operating pressure should be, start at a lower operating
pressure. Reduce the pressure by turning the valve counterclockwise (unscrew outward)
before starting the chiller.
With the chiller fully connected and running, read the pressure gauge and turn the regulator
to the desired pressure. If required, an optional external pressure reducing assembly is
available for this pump to reduce the pressure to 10 - 45 psi.
2.4 Setting Up a Closed System or Cooling Coil to the Chiller
1. Connect your closed cooling system to the chiller with hoses or pipes. The direction of the flow
through the system can be controlled by the way the hoses or pipes are connected to the chiller.
The “Inlet” will draw liquid into the chiller; the “Outlet” will pump liquid out.
2. Turn the access panel screws to remove the top cover and expose the reservoir. Turn the filler
cap and lift up to remove. Use a funnel to fill the reservoir with fluid. When full, remove the
funnel, but do not replace the cap at this time. Check hoses and fittings for tightness and be
sure there are no bends or crimps in the hoses.
3. Plug the chiller into the proper AC outlet (unit's electrical requirements on rear of unit). Press
the POWER ONbutton. The chiller will begin pumping liquid through your system. Check for
leaks.
4. With the pump running, the reservoir's fluid level will decrease as the closed system begins to fill.
Add a little fluid at a time until the level in the reservoir stops going down. This means that your
system is filled and the air has been purged from it. Replace the reservoir cap and turn it
clockwise to lock it. Recheck the cap for tightness.
Note: When chillers with the standard magnetic drive centrifugal pump are connected to an external
apparatus with a built-in flow shut-off, an external bypass loop assembly (pt.# 510-147) may be
needed if operating below 20°C. This bypass assembly continues fluid circulation to and from the
pump even though the main flow to the external apparatus has been blocked.
2.5 Setting Up an Open Bath System to the Chiller
1. Connect hoses to the Inlet and Outlet fittings on the back of the chiller. The "Inlet" draws fluid
into the chiller, the "Outlet" pumps fluid out. Fill the open bath. Considering this flow, position
the hoses in your bath for a good circular flow and stirring motion.
2. Turn the panel screws to remove the top cover and access the reservoir. Turn and lift the filler
cap to remove. Use a funnel to fill the reservoir with the same fluid in your bath. This primes the
pump and helps establish a flow when the chiller is turned on.
3. Replace the reservoir cap and turn to lock it. Check for tightness. Check all hoses and fittings.
Be sure there are no bends or crimps in the hoses, and that the hose attached to the chiller's
inlet is submerged near the bottom of the bath. Secure the inlet and outlet hoses to the open
tank so they do not move when pumping starts. The bath's fluid level will drop slightly as the
hoses in the system fill up with fluid. The bath's fluid must cover the chiller's inlet hose.
4. Plug the unit into the proper AC outlet (unit's electrical requirements on rear of unit). Press the
Power On button. The chiller will begin pumping fluid through your system. Check for leaks.
8

Section 3 - Operation
3.1 Power Requirements
Caution! Be sure that the power supply is the same voltage as specified on the nameplate
With the chiller plugged in (before pressing the POWER ONbutton), the display responds by showing
standby (....). If there is no response, check that the circuit breaker on the rear of the chiller is in the
ON position. An extension cord is not recommended.
3.2 Temperature Setting and Adjustments
After setting up and filling the chiller:
1. Press the POWER ONbutton. The LED display indicates (8888), the power up self test. When the
chiller is turned on, there is a 60 second time-out period. During this time the controller is
performing a self-diagnostic and a balancing of pressure across the compressor inlet and outlet.
(a balanced system reduces the AC current required to start up the compressor and will result in
an extended compressor life.) The pump is active during the start delay period. When the time
out period reaches zero, the compressor starts and the chiller is then fully operational.
Upon completion of the self test, the actual fluid temperature is displayed. Your desired
operating temperature can now be set.
2. Press the SET/MENU button. The degree lights flash indicating the temperature can be set or
changed. Turn the SETTING ADJUSTMENT knob to the desired setting. This setting is accepted
after pressing the SET/MENU button or will be automatically accepted after a few seconds of
keypad inactivity. The degree light stops flashing and the display shows the actual temperature.
3. The SET TEMPERATURE may be checked at any time by pressing and releasing the SET/MENU
button. Allow sufficient time for the chiller to stabilize at the desired temperature.
3.3 Selection of Celsius or Fahrenheit
To change the readout to °C or °F:
1. Press and hold the Set/Menu button until the display reads “UNITS”.
2. Press Set/Menu again then turn the Setting Adjustment knob and select °C or °F.
3. Press Set/Menu or the setting will be accepted after a few seconds.
9
PRESSURE GAUGE,
(On Positive Displacement
Pump models only)
SET/MENU
BUTTON
(For models with
optional heater only) LED
DISPLAY °C OR °F DISPLAY SETTING ADJUSTMENT KNOB
POWER
BUTTONS
Front Face Plate

3.4 Setting the Readout High Limit
This feature limits the readout setability so the operating temperature setting cannot easily be set
above the High Limit you select. It is not an over temperature feature which shuts off the chiller.
To set the readout High Limit:
1. Press and hold the Set/Menu button until the display reads “UNITS”.
2. Turn the Setting Adjustment knob until the display reads “HI-L”.
3. Press the Set/Menu button, enter the desired value using the Setting Adjustment knob.
4. Press Set/Menu and the display will again read "HI-L". The Setting Adjustment knob can be
turned to access another menu option or you can wait until the entered value has been
accepted. When the value is accepted, the degree light will stop flashing and the fluid
temperature will be displayed.
3.5 Controller Display Messages
Display Message
--Normal Screens--
.... Standby mode. Unit plugged in. Power switch OFF, rear circuit breaker on
8888 Power up self test displayed when power button initially pressed on
--Menu Screen--
Unit Change to °F or °C
Unit/Hi-L Limits operating temperature setability
--Error Screens--
E-tF Triac (alternistor) failure
DEF Displayed when chiller is reset to factory default settings
--Optional Equipment (Flow or Float Switch)--
E-nF No Flow
E-FL Low Level Fluid
3.6 Draining the Unit
Press the Power Off button and unplug the chiller. Remove drain plug and reservoir cap and allow
unit to drain. Syphon or use a small manual pump to remove all fluid from the reservoir.
Run the unit intermittently (5 to 10 seconds each time) to pump the water from the system. Stop
pumping when the fluid is reduced to a trickle. Running for a longer period will cause damage to the
positive displacement pump. Open the reservoir and use suction or a hand pump to remove any
remaining water.
Prior to storage or shipping: Water MUST be removed from ALL parts of the chiller system, or
an ANTIFREEZE must be added to insure that internal damage does not occur.
3.7 Controller Default Settings
To return to the factory default values:
1. Press and hold the Power On button, then turn off at the circuit breaker.
2. Still holding Power On, hold the Set/Menu button while turning the unit on by the circuit breaker.
3. The controller will display “DEF” and go to the standby mode.
4. Your set temperature and other settings will have to be reset.
10