Unitrol 8000 User manual

PROCESS WATER CHILLER
MODEL #8000, #8012

WARRANTY
PARTS: Unitrol warrants this chiller to be free of defects in materials
that effect operation, for a period of one year from date of shipment
from factory, if said equipment has not been altered or abused by
customer and is being used for the purpose that the equipment was
designed for. Parts will be shipped, FOB Northbrook, Illinois.
Defective parts will be returned to Unitrol at customer’s expense
when so requested by Unitrol.
LABOR: Necessary warranty labor is covered for a period of 90 days
from the date of shipment from factory, if said equipment has not
been altered or abused by customer and is being used for the
purpose that the equipment was designed for. Parts will be replaced
or repaired, at manufacturer’s option on any parts found to be
defective. Unitrol shall not, without its prior written approval, be
liable for any costs involved in field repairs. Transportation of
equipment to or returning from Unitrol shall be at customer’s
expense.
Alternately, Unitrol may elect to send a local refrigeration contractor
to do warranty service. In this case, Unitrol will pay contractor
directly.
To be covered by this warranty, please follow the following
procedure:
1. Contact the Unitrol service department at 847-480-0115 to discuss
the problem you are having with this chiller.
2. If Unitrol concurs that this is a warranty issue, and the chiller is more
than 90 days from date of factory shipment, a Unitrol representative
will either arrange to have a replacement part shipped, or authorize a
locally purchased replacement at a pre-agreed price that will be
reimbursed by Unitrol.
3. If Unitrol concurs that this is a warranty issue, and the chiller is less
than 90 days from date of factory shipment, a Unitrol representative
will have a factory approved service technician dispatched
to make repairs under the above terms. Alternately, the
Unitrol representative will direct that the chiller be
returned to the factory for repairs.
No other warranty, either written or implied, shall cover this
equipment, and Unitrol shall not be liable for any damage
caused to other equipment or personnel due to failure of this
product. Unitrol reserves the right to change specifications at
any time.

UNITROL PROCESS
WATER CHILLER
Thank you for purchasing this Unitrol process water chiller. It
was manufactured with pride in our Northbrook, Illinois factory.
Unitrol also manufactures the Unitrol line of RESISTANCE
WELDING CONTROLS. This line includes controls that include
safety systems to protect the welding machine operator, as well
as quality control features that allow you to produce a large
volume of weldments that will match the highest quality
requirements.
This Unitrol water chiller has been designed to operate under
the most severe industrial conditions. Please observe the
installation instructions to be sure that this chiller will provide
years of superior service.
MODEL NUMBER:
8012
NOMINAL CAPACITY:
6,000 BTU/HR
SERIAL NUMBER:
1121298
DATE OF MANUFACTURE:
11/2021
REFRIGERANT:
R134a
PUMP: 1/3HP, 3GPM @35PSI Max.
SERVICE:
8000 = 115V. 16A
8012 = 115V, 20A

TABLE OF CONTENTS
Installation…………………………………..
1
Initial Startup………………………………..
3
Setting Temperature Operation…………..
3
Temperature Controller Operation……….
4
Diagnostics
Low Water Level Switch……………
5
Low Freon Fault…………………….
6
High Freon Fault…………………....
6
Maintenance………………………………..
8
Schematic Drawing………………………...
8
Replacement Parts………………………...
10
Maintenance Record Sheet……………....
12

UNITROL MODEL #8000, 8012
CHILLER
INSTALLATION
1
1. Carefully remove chiller from the shipping carton and
inspect for external damage. If any damage is seen, do
not continue until a representative of the freight company
views the damage, and a claim to the freight company has
been filed.
2. Install the chiller in a location that will keep the air intake
(front of chiller with air filter) and air exhaust (back of
chiller with expanded metal plate) at least 36” from the
nearest wall. This is required to allow maximum air
movement over the condenser coil.
3. Remove the water tank cover and untie the water level
switch float. Leave the water tank cover off for now.
4. Locate two ¼” NPT bulkhead fittings at the back of the
chiller. Install hose barbs and connect as marked to the
welder. Use Teflon tape on fittings to prevent excessive
force being required on installation and to make a better
seal.
FAILURE TO ALLOW MINIMUM WALL CLEARANCE WILL
RESULT IN HIGH FREON TEMPERATURES AND WILL VOID
WARRANTY.
THIS CHILLER IS DESIGNED FOR INSIDE
INSTALLATION. ONLY CHILLERS PURCHASED WITH
THE –OS (OUTSIDE) KIT CAN BE INSTALLED
OUTSIDE IN AREAS WHERE THE AIR TEMPERATURE
CAN FALL BELOW 45ºF, AND SUCH INSTALLATION
WILL VOID THE WARRANTY.

UNITROL MODEL #8000, 8012
CHILLER
INSTALLATION
2
5. Fill stainless steel tank with tap water until it is about 1”
below the top of the tank.
6. Plug the power line cord into a 20A 115V grounded
outlet.
DO NOT ELIMINATE THE GROUND
PIN ON THIS CORD. DO NOT
OPERATE THIS CHILLER WITHOUT A
PROPER GROUND THROUGH THE
LINE CORD.

UNITROL MODEL #8000, 8012
CHILLER
INSTALLATION
3
INITIAL STARTUP
1. Before starting the chiller, have a source of water available
to keep the tank filled during the first few minutes of
operation.
2. Turn the control switch to the ON position. The
temperature controller should turn on, and the water pump
should start operating. Because you will be filling the
outside hoses and machine internal piping with water,
keep adding water until the level remains about 1” below
the top of the tank.
SETTING TEMPERATURE
CONTROLLER
The temperature displayed on the temperature controller is
the water tank temperature.
1. Push the SEL button on the TEMPERATURE
CONTROLLER. The display will show SV.
2. Press the SEL button again and the SV value will be
displayed.
DO NOT ALLOW THE PUMP TO GO DRY.
OPERATING A CHILLER PUMP WITHOUT
WATER WILL BURN THE PUMP OUT. CHECK TO
BE SURE THAT THE WATER LEVEL FLOAT
TURNS THE PUMP OFF AND SOUNDS THE
ALARM WHEN PUSHED DOWN.

UNITROL MODEL #8000, 8012
CHILLER
INSTALLATION
4
3. Push the ▲ or ▼ to select the desired turn-on
temperature for the chiller. Note that this chiller has been
factory set to allow a minimum temperature of 55ºF.
4. Push and release the SEL button. This will lock in the new
setting.
5. Then push the ▼ button and SEL button at the same
time.
6. Release both buttons. The display will briefly show 00,
and then the tank temperature.
TEMPERATURE
CONTROLLER OPERATION
1. When the water tank is at least 3ºF above the SV
(customer set point), the compressor will start operating.
At this time, a small red square light marked OUT located
just above the SEL button on the controller will glow.
2. When the water tank temperature reaches the SV value,
the compressor will turn off and the red OUT light will stop
glowing.
If any problems are incurred during this installation, contact the
Unitrol service department at 847-480-0115. Please have the
model number and serial number ready.

UNITROL MODEL #8000, 8012
CHILLER
DIAGNOSTICS
5
When any of the following faults occur, the following will
happens:
1. An alarm sounds
2. The water pump stops operating
3. The refrigeration system stops operating
LOW WATER LEVEL SWITCH:
The LOW WATER LEVEL SWITCH is located on the front
wall of the water tank. It floats upward when water level is
above a minimum level, and falls down when the water falls
below the required minimum level.
WHY THE LOW WATER LEVEL SAFETY
SWITCH IS IMPORTANT
If the water level in the tank falls below the
factory minimum level, air will be sucked into
the water pump and eventually allow it to
operate dry. When this happens, the pump
seals and vanes will burn out to destroy the
pump head. Permanent damage can easily
occur to the compressor at this point.
DO NOT DEFEAT THE WATER LEVEL SAFETY
SWITCH!

UNITROL MODEL #8000, 8012
CHILLER
DIAGNOSTICS
6
LOW FREON FAULT:
The Freon pressure in the sealed refrigeration system has
fallen below the setting on the LOW FREON safety switch.
When this switch trips, it is probable that it will start again for a
few seconds, go to fault, etc. This indicates that the Freon level
is low, but that Freon is present. This conditions is caused by a
Freon leak within the sealed system.
Contact a certified refrigeration technician to check the
system, find and repair the leak, and charge it properly.
HIGH FREON FAULT:
The Freon pressure in the sealed refrigeration system has
gone above the setting on the HIGH FREON safety switch.
When this switch trips, the chiller will reset in a few minutes.
This HIGH FREON FAULT can be caused by one of the
following:
DIRTY AIR INTAKE FILTER: If the airflow across the
condenser coil is below a minimum requirement, the ability for
heat to be removed from this coil will be greatly reduced. The
temperature of the Freon in this coil will continue to rise until
the set pressure value has been exceeded. This filter should be
cleaned with soapy water once per week for normal factory
conditions, or more frequently for factories that have a large
dust or grinding dust content in the air.
DIRTY CONDENSER COILS: If dirt has been trapped on the
surfaces of the condenser coil’s fins, the ability for these
surfaces to transfer air to the passing air stream will be greatly
reduced. See the maintenance section for coil cleaning
directions.

UNITROL MODEL #8000, 8012
CHILLER
DIAGNOSTICS
7
LOW AIR FLOW ACROSS THE CONDENSER CAUSED BY
INSTALLATION OF CHILLER TOO CLOSE TO A WALL: If
the air intake (air intake filter) is less than 36” from a wall, or the
air exhaust grill on the back of the chiller is less than 36” from a
wall, air flow will be restricted and will reduce the ability of this
air to remove heat from the condenser coil. The chiller has to
be moved to eliminate this problem.
USE OF AN INTAKE AIR FILTER DURING EXTREMELY
HOT DAYS: If the room temperature exceeds 95ºF, it is
possible that the small reduction caused by even a clean intake
air filter will cause the system to overheat and trip the HIGH
FREON safety switch. Remove the air filter and replace it when
air temperature falls below 90ºF.
THE NEED FOR MORE AIR FLOW OVER THE CONDENSER
COIL: In extreme cases of high room temperature and
restricted air flow around the chiller, it might be necessary to
use an additional fan to force air across the condenser coil.
This can be done using a commercial fan blowing air into the
front of the coil (where air filter is located), or by installing a
factory fan booster kit. Consult the Unitrol service department
on this.

UNITROL MODEL #8000, 8012
CHILLER
SCHEMATIC
8

UNITROL MODEL #8000, 8012
CHILLER
MAINTENANCE
9
CLEAN THE CONDENSER: Inspect the evaporator coil fins
(behind the air intake filter) every 3 months of operation. If
there is evidence of dirt or grease buildup, clean the evaporator
fins using a water hose from the outside. Flush as much of the
trapped debris as possible from between the fins.
If there is too much buildup for reasonable cleaning, use a
commercially available aluminum fin spray solvent such as
Nonacid condenser coil cleaner, W.W. Grainger #5W403.
Follow directions on the product label.
WATER TANK CLEANING: Remove the cover of the water
tank once every 6 months and inspect to see if there is a large
buildup of material in the water. Remove as much material as
possible.
OTHER MAINTENANCE:
Bearings on the water pump are sealed and do not require
periodic oil or grease.
There are no other periodic service components in the system.
ONLY A CERTIFIED REFRIGERATION TECHNICIAN
SHOULD BE ALLOWED TO SERVICE THE SEALED
REFRIGERATION SECTION OF THIS CHILLER

UNITROL MODEL #8000 CHILLER
MAINTENANCE RECORD
10
DIRECTION BOOK: 8000-50= Direction book
WATER COMPONENTS:
800P-01 = Water pump and motor, 1/3HP
8000-01D = Water Pump and clamp only (no motor)
8000-01B = Water pump motor only (no pump), 1/3HP
8000-01C = Pump coupler
8000-05 = Water pressure dump valve
ELECTRICAL COMPONENTS:
8000-02A = Temperature controller, 115V
8000-03 = Control relay (2 in chiller)
8000-04 = Fault signal
8000-06 = Low water safety switch
8000-07 = ON/OFF switch
8000-08= Line cord with plug
8000-FR = Air intake filter

UNITROL MODEL #8000 CHILLER
MAINTENANCE RECORD
11
REFRIGERATION COMPONENTS:
COMPRESSOR:
80RF-01 = Replacement compressor for model 8000
80RF-01/.5=Replacement compressor for model 8012
80RF-01A= Complete condenser with compressor,
receive, and fan for model 8000.
80RF-01A/.5 = Complete condenser with compressor,
receiver, and fan for model 8012
EVAPORATOR:
80RF-30 = Brazed plate only for model 8000 and 8012
80RF-30A =Brazed plate assembly with expansion
valve and equalizer tube brazed for model 8000
80RF-30A/.5 =Brazed plate assembly with expansion
valve and equalizer tube brazed for model 8012
EXPANSION VALVES:
80RF-40 = Expansion valve for model 8000
80RF-40/.5 = Expansion valve for model 8012
REFRIGERATION LIQUID LINE FILTER/DRIER:
80RF-50 = Sealed, for standard installation
80RF-50A= Replicable core, for burn-out installation,
includes 2 cores
REFRIGERATION SIGHT GLASS: 80RF-60
Note: Unitrol will only sell
refrigeration components to certified
refrigeration technicians

UNITROL MODEL #8000 CHILLER
MAINTENANCE RECORD
12
DATE
PROBLEM
RESOLUTION

13

UNITROL ELECTRONICS, INC.
702 LANDWEHR ROAD
NORTHBROOK, ILLINOIS
60062
847-480-0115
[email protected]