HP Refrigerated Recirculating Chillers Bedienungsanleitung

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

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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.

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

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

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.

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.

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.

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.

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