Conair UGH031-0209 manual

EarthSmart TM ECM Series, 0.50 to 0.75 ton models Corporate Office: 724-584-5500 l Instant Access 24/7 (Parts and Service): 800.458.1960 l Parts and Service: 814.437.6861 USER GUIDE UGH031-0209 www .conairgroup.com[...]

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 receiv ed it in the User Guide. Our service department uses this infor- mation, along with the manual number , to provide help for the speci[...]

T able of Contents 1-1 Introduction Purpose of the user guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 How the guide is organized . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 Y our responsibilities as a user . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 A TTENTION: Read this so no one ge[...]

Stopping the chiller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4 Changing tempera ture units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5 Chiller opera tion sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6 Resetting the high pressure s witch of the compressor . . . . . .[...]

B Appendix Safety adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1 C Appendix Water quality control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-1 D Appendix Chiller ca pacity and derate chart . . . . . . . . . . . . . . . . . . . . . . . . . . D-1 E Appendix Pressure-temperature[...]

iv l T able of Contents[...]

Introduction Purpose of the user guide . . . . . . . . . . . . . . 1-2 How the guide is organized . . . . . . . . . . . . . 1-2 Y our responsibilities as a user. . . . . . . . . . . 1-3 A TTENTION: 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 the EarthSmart ECM Series Chiller and explains step-by-step ho w to install, operate, maintain and repair this equipment. Before installing this product, please take a fe w moments to read the User Guide and revie w the diagrams and safety information in the instruction packet. Y ou also shoul[...]

Introduction l 1-3 Y our Responsibility as a User Y ou must be familiar with all safety procedures concerning installation, opera- tion and maintenance of this equipment. Responsible safety procedures include: • Thorough revie w of this User Guide, paying particular attention to hazard warnings, appendices and related diagrams. • Thorough revie[...]

A TTENTION: Read this so no one gets hurt W e design equipment with the user’ s safety in mind. Y ou can avoid the potential hazards identified on this machine by follo wing 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[...]

1 Introduction Introduction l 1-5 CAUTION: Hot Surfaces Always protect yourself from hot surfaces when working on the chiller , especially when working on or around the compressor and condenser . These devices can be over 160°F {71°C}. Allow these devices to cool before performing any maintenance or troubleshooting. WARNING: Refrigerant hazard On[...]

1-6 l Introduction[...]

Description l 2-1 Description What is the EarthSmart ECM Series Chiller? . . 2-2 T ypical a pplications . . . . . . . . . . . . . . . . . . 2-2 Limitations . . . . . . . . . . . . . . . . . . . . . . . . 2-3 How it works: Process circulation . . . . . . . . 2-4 Refrigeration circula tion . . . . . 2-5 Component listing . . . . . . . . . 2-6 Specifi[...]

What is the EarthSmart ECM Series Chiller? The Conair EarthSmart ECM Series Chillers provide self-contained sources of chilled water and are a vailable with compressor ranges of 0.5 Hp or 0.75 Hp (nominal capacities of 0.41 tons or 0.70 tons of refrigeration). IMPORT ANT : Nominal chilling capacities are based on 95°F {35°C} ambient air condition[...]

Description l 2-3 2 Description Limitations Conair EarthSmart ECM Series Chillers are chosen based on the cooling load, ambient temperature and cooling temperature. ● Cooling load - Choose a chiller that has 0 - 10% more cooling capacity than the process load to be chilled. ● Ambient temperature - The chiller’ s air-cooled condenser requires [...]

2-4 l Description How it W orks: Process Circulation Hot fluid from the process enters the chiller through the “From Pr ocess” inlet into the chiller’ s reservoir . Pump mov es fluid from the reservoir through ev aporator where it is chilled. Fluid is chilled in the ev aporator and exits through the “T o Process” outlet, returning to the [...]

2 Description Description l 2-5 How it W orks: Refrigerant Circulation The ev aporator extracts heat from the process fluid, causing the refrigerant to vaporize (e vaporate) into a gas. V aporized refrigerant trav els to the compressor, where the low-pressure v apor is compressed into a high-pressure, high-temperature vapor . The high-pressure, hig[...]

How it W orks: Component Listing Water system • Motor/Pump assembly - The motor/pump assembly circulates chilled coolant through the process loop. The pump assembly is b uilt with brass to maintain water quality . Refrigeration system • Compressor - Hermetic compressor tak es low-pressure, lo w-temperature refrigerant gas and compresses the gas[...]

• Evaporator - The ev aporator is a brazed plate heat exchanger where the liquid refrigerant is allowed to e vaporate (boil of f) to absorb the heat (BTU) from the process fluid. As the heat is absorbed, the process fluid is chilled. • High/Low Pr essure Switches: The high/low pressure switches protect the refrigeration system from unsafe opera[...]

2-8 l Description Specifications: EarthSmart TM ECM Series Chillers A B C TPHS039-1208 MODEL ECM-0.5 ECM-0.75 Perf ormance characteristics Capacity* tons 0.41 0.70 Compressor Hp {kW} ✝ 0.5 {0.37} 0.75 {0.56} Pump Hp {kW} 0.25 {0.19} 0.5 {0.37} Chilled water flow ‡ gpm {lpm} 0.9 {3.4} 1.7 {6.4} Chilled water pressure ‡ psi {bar} 60 {4.1} 60 {4[...]

Description l 2-9 2 Description Pump Cur ve: EarthSmart TM ECM Series Chillers 25 50 75 100 125 150 175 200 225 250 25 20 30 40 50 60 70 80 90 100 110 120 130 140 10 0.00 0.05 0.10 0.15 0.20 0.25 0.30 0.35 0.40 0.45 0.50 0.55 0.60 0.65 Outlet Pressure* (PSI) Horsepower Flow Rate (GPH at 1725 RPM) SPECIFICA TION NOTES * Pump curves do not reflect pr[...]

2-10 l Description[...]

Installation l 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 . . . . . . . . . . . . . . . . . . . 3-6 Drain connection . . . . . . . [...]

3-2 l Installation Unpacking the Boxes The EarthSmart ECM Series Chiller comes fully assembled in a single crate. Units are shipped with the casters attached. 1 Carefully uncrate the chiller and its components. 2 Remove all packing material , protecti ve paper , tape and plastic. Compare contents to the shipping papers to ensure that you hav e all [...]

Installation l 3-3 3 Installation W arnings and Cautions WARNING: Improper installation, operation, or servicing may result in equipment damage or personal injury . This equipment should only be installed, adjusted and ser viced by a qualified technician who is familiar with the construction, opera tion and potential hazards of this type of machine[...]

Preparing for Installation Plan the location for the chiller and prepare the area properly . Position the chiller as close to the process machine as possible. Place the chiller in position near the process machine so that coolant lines can be connected from the process machine to the chiller and back. Make sur e the area where the chiller is instal[...]

Installation l 3-5 3 Installation Making Process Plumbing Connections All process piping materials (such as hoses, rigid piping, valv es or filters) used with process water piping circuitry must be rated for 100°F {37.8°C} minimum temperature and 150 PSI {10.3 bar} minimum pressure. All such materials must hav e the equiv alent or larger diameter[...]

3-6 l Installation Filling the Chiller The chiller is shipped without coolant. The chiller is manually f illed during instal- lation using water as its coolant. For atypical process temperatures belo w 45° F {7.2°C}, use the table below to determine the percentage (by volume) of glycol needed for the process tempera- ture that is required. Mix th[...]

Installation l 3-7 3 Installation Drain Connection T o drain the chiller for storage or transport: 1 Rotate the chiller’ s drain valve counterclockwise. If using chemicals or additiv es with your process coolant, observe local disposal laws and re gulations. 2 Close the chiller’ s drain valve by turning it clockwise once f inal ev acuation of a[...]

3-8 l Installation Checking the Refrigerant Charge WARNING: Refrigerant hazard Only certified refrigerant technicians should examine and correct problems involving the refrigerant circuit. All chillers are fully charged with R-134A refrigerant from Conair . Y our chiller’ s model nameplate identifies the type and amount of total refrigerant char [...]

Connecting the Main P ower The Conair EarthSmart ECM Chiller uses standard 115 V olt, 60 Hz or 220 V olt, 60Hz single-phase power , depending on model. T o connect the the main power to the chiller: 1 Connect the chiller’ s plug into a properly-sized and rated electrical outlet. IMPORT ANT : Always refer to the wiring diagrams that came with your[...]

3-10 l Installation[...]

SECTION 4 4 Operation Operation EarthSmart ECM Series Chiller: Control descriptions . . . . . . . . . . . . . . . 4-2 Starting the chiller . . . . . . . . . . . . . . . . . . 4-3 Stopping the chiller . . . . . . . . . . . . . . . . . . 4-4 Changing temperature units . . . . . . . . . . . . 4-5 Chiller operation sequence . . . . . . . . . . . . . 4-[...]

12 % SD EarthSmart ECM Chiller: Control Descriptions Hot-Gas Bypass Status Indicates the status of the Hot-Gas Bypass valv e. Actual Chiller T emperature Shows the (process) actual temperature value. On/Off T oggle Switch Used to turn the power to the chiller on or off. Alarm Indication Indicates the alarm sta- tus. (High T emperature Alarm only .)[...]

4 Operation Operation l 4-3 Starting the Chiller T o start the chiller: 1 T oggle the power switch to the On or “ I ” position. The control display will illuminate. Facing the chiller’ s control, the “T o Process” actual temperature will be on the left, the setpoint temperature is on the right. See Operation section entitled, Chiller Sequ[...]

4-4 l Operation Stopping the Chiller T o stop the chiller: 1 T oggle the power switch to the Off or “O” position. Off P osition 12 % SD IMPORT ANT : Do NO T rapidly cyc le the chiller’ s po wer on and off (short cyc le). Once the power has been turned off, wait at least three (3) minutes before c ycling the chiller’ s power back on.[...]

4 Operation Operation l 4-5 Changing T emperature Unit T o stop the chiller: 1 Press the gr een “Return” button once to access the T emperature Units Selection screen. Press the ▲ or ▼ buttons to toggle between fahrenheit and celsius temperature units. 2 Press the “Inf inity” button to lock in the selection and retur n to the Main scree[...]

4-6 l Operation Chiller Operation Sequence The EarthSmart ECM Series Chiller has a unique user interface that controls the process temperature and prev ents refrigeration migration during compressor off times. When the main power is connected: 1 Depending on the state of the refrigeration system, the compr essor may turn on momentarily upon connect[...]

Operation l 4-7 4 Operation Chiller Operation Sequence (continued) 5 The condenser fan can energize anytime the toggle switch is in the “On” or “ I ” position. The fan is controlled by the fan cycling (high refrigeration) pressure switch. This switch maintains the high side refrigeration pressure under cooler ambient temperatures and lower [...]

4-8 l Operation Resetting the High Pressure Switch of the Compressor The high refrigeration safety pressure switch shuts off the compressor immediately when the high refrigeration pressure reaches 230 PSI {15.9 bar} without going through pump down during a lo w pressure cycle. If the high pressure switch trips, it must be manually reset by pressing[...]

Maintenance Preventative maintenance schedule . . . . . . . 5-2 Checking electrical connections . . . . . . . . . . 5-4 Cleaning the brazed plate ada pter . . . . . . . . 5-5 Cleaning the air -cooled condenser . . . . . . . . 5-7 Checking the reser voir level . . . . . . . . . . . . 5-9 Cleaning the pump strainer . . . . . . . . . . . . 5-10 Checki[...]

5-2 l Maintenance Preventative Maintenance Schedule Daily , or as often as needed ❒ Checking process fluid le vel in the pump tank Check the process fluid lev el in the water lev el gauge on the back of the chiller . If lo w , see Maintenance section entitled, Checking the Reservoir Level. ❒ V erifying pump discharge pressur e While the pump is[...]

Maintenance l 5-3 Preventative Maintenance Schedule (continued) Monthly ❒ Inspecting cooling water treatment system If your chiller uses a cooling water treatment system, maintain proper chemi- cal lev els and follow the recommendations of your water treatment specialist. Change water in the reserv oir tank monthly to reduce water hardness. ❒ C[...]

5-4 l Maintenance Checking Electrical Connections WARNING: Electrical Hazard Before performing any work on this item, disconnect and lock out electrical power sources to prevent injury from unexpected energiza tion or startup. Be sure tha t power to the chiller is OFF when doing any maintenance on the chiller . Follow all safety rules when performi[...]

Cleaning the Brazed Plate Ev aporator Minerals and other contaminants produce deposits, scales, slime or algae on the heat transfer surfaces exposed to w ater . Fouled surfaces could result in decreased cooling capacity . Implement a water treatment program to slow the fouling. CAUTION: Hot Surf aces Always protect yourself from hot surfaces when w[...]

5-6 l Maintenance Cleaning the Brazed Plate Ev aporator (continued) 5 Remove R TD from bottom of evaporator . 6 Connect 3/8-inch tubing to the 3/8-inch connections of the heat exchanger . SEE below to install customer -supplied chemical pump and solution fitted to the heat exchanger . 7 Back-flush the solution through the heat exchanger and the chi[...]

5 Maintenance Cleaning the Air -Cooled Condenser WARNING: Electrical Hazard Before performing any work on this item, disconnect and lock out electrical power sources to prevent injur y from unexpected energization or startup. Be sure that power to the chiller is OFF when doing an y maintenance on the chiller . Follow all safety rules when performin[...]

Cleaning the Air -Cooled Condenser (continued) 7 Check the air filter . If the filter is blinded or torn, replace the filter . 8 Replace the chiller’ s side panels and then the top lid by replacing the four (4) retaining bolts . 9 Reapply main power . CAUTION: W ear eye protection. If you use compressed air to clean the equipment, you must wear e[...]

Maintenance l 5-9 Checking Reser voir Level WARNING: Electrical Hazard Before performing any work on the chiller , disconnect and lock out electrical power sources to prevent injur y from unexpected energization or startup. Be sure that power to the chiller is OFF when doing an y maintenance on the chiller . Follow all safety rules when performing [...]

Cleaning the Pump Strainer EarthSmart Chillers use a rotary pump to flow process coolant through their internal piping and to the process. A strainer on the pump may periodically need cleaning, depending upon the quality of the process coolant. WARNING: Electrical Hazard Before performing any work on the chiller , disconnect and lock out electrical[...]

Cleaning the Pump Strainer (continued) 6 Remove the strainer fr om its housing. 7 Inspect the strainer for holes or blinding, clean or replace as necessary . 8 Re-install the strainer and strainer cap. Properly seal all piping with approv ed T eflon tape or pipe dope. 9 Check to ensure no leaking has occurr ed before returning the chiller to normal[...]

5-12 l Maintenance Checking the Refrigerant Charge and Quality WARNING: Refrigerant Hazard Only certified refrigerant technicians should examine and correct problems involving the refrigerant circuit. All chillers are fully charged with R-134A refrigerant from Conair . Y our chiller’ s model nameplate identifies the type and amount of total refri[...]

T roubleshooting Before beginning . . . . . . . . . . . . . . . . . . . . 6-2 A few words of caution . . . . . . . . . . . . . . 6-3 DIAGNOSTICS How to identify the cause of a problem . . . . 6-3 Alarms . . . . . . . . . . . . . . . . . . . . . . . . . 6-4 T roubleshooting . . . . . . . . . . . . . . . . . . . . 6-5 Checking or replacing the temper[...]

Before Beginning Y ou can av oid most problems by following the recommended installation and maintenance procedures outlined in this User Guide. If you do hav e a problem, this section will help you determine what caused it and how to f ix it. ❏ Diagnose causes from the contr ol panel. 1 Note the alarm and press the “Inf inity” button once to[...]

6 T roubleshooting A F ew Words of Caution Improper correctiv e actions can lead to hazardous conditions and should nev er be attempted to sustain production. WARNING: Only a qualified electrical technician should e xamine and correct problems that require opening the chiller’ s electrical enclosure or using electrical wires to diagnose the cause[...]

6-4 l T roubleshooting Alarms If the red alarm LED is illuminated, an alarm is activ ated. The chiller has automat- ically pumped down because it has detected a serious problem that could damage your process or chiller . Note that the alarm must be ackno wledged before the con- trol will resume operation by pressing the “Infinity” b utton. Prob[...]

T roubleshooting l 6-5 6 T roubleshooting T roubleshooting Problem The chiller will not start. (Control not illuminated) Pump will not start. P ossible cause T ripped circuit breaker . Incorrect incoming voltage. The power toggle switch is not turned to the “On” or “ I ” position. Open motor winding. Internal ov erload has tripped. Loose wi[...]

T roubleshooting (continued) Problem Compressor will not start. P ossible cause High pressure switch has been tripped. Circuit breaker has been tripped. Loose wire connection or defectiv e start capacitor . The actual “T o Process” temperature is below the setpoint. Damaged or defectiv e start capacitor . Poor water flo w . Damaged or defectiv [...]

T roubleshooting (continued) Problem Chiller shuts down due to a High Pressur e switch alarm. Chiller shuts down due to a Low Pressur e switch. P ossible cause Low air flo w across the condenser . Fan not operating. High ambient temperature. Insuff icient clear space around unit. Clogged air filter . Attempting to operate the chiller with process c[...]

Checking or Replacing the T emperature Sensor The EarthSmart ECM Series Chiller uses a R TD sensor to monitor the temperature of the process coolant. T o check or replace an R TD sensor: 1 Disconnect and/or lockout the main power supply . 2 Locate the R TD sensor . 3 Check the sensor’ s position and condition. T emperature readings will be incorr[...]

T roubleshooting l 6-9 Checking or Resetting the Circuit Breakers The EarthSmart ECM Series Chiller uses electrical circuit break er to protect the chiller from ov erloads or improper operating conditions. T o check or reset the chiller’ s circuit breakers: 1 Disconnect and lockout the main power supply . 2 Remove the chiller’ s top lid, by fir[...]

A-1 l A ppendix W e’re Here to Help Conair has made the largest in vestment in customer support in the plastics indus- try . Our service experts are av ailable to help with any problem you might ha ve installing and operating your equipment. Y our Conair sales representative also can help analyze the nature of your problem, assuring that it did n[...]

Appendix l A-2 Equipment Guarantee Conair guarantees the machinery and equipment on this order , for a period as defined in the quotation from date of shipment, against defects in material and workmanship under the normal use and service for which it was recommended (except for parts that are typically replaced after normal usage, such as f ilters,[...]

B-1 l A ppendix Safety Adjustments T o ensure safe and eff icient operation at lower setpoints, adjustments of the low pressure switch from f actory settings is required. The table belo w lists the appropriate settings. The low pressure switch serv es as the mainline defense against freezing. It shuts down the chiller if the coolant temperature e v[...]

Appendix l C-1 W ater Quality Control Insuff icient or improper water treatment can damage the EarthSmart ECM Chiller . A certified w ater treatment specialist should be consulted for your particular application. It is the owner’ s responsibility to prev ent damage from foreign material or inadequate water treatment. The two main points to consid[...]

D-1 l A ppendix Chiller Capacity and Derate Chart If operation of the chiller is less than 45°F {7.2°C}, a glycol and water mixture is required. See Operation section entitled, F illing the Chiller . Ambient conditions affect air -cooled chiller operation and capacity . Standard rating is at 95°F {35°C} entering air temperature. For ambient air[...]

Appendix l E-1 Pressure-T emperature Chart for R-134A Refrigerant Refrigerant Pressure (PSIG) 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 90 95 100 105 110 115 120 125 130 135 140 145 150 155 160 170 180 190 200 210 220 230 Saturated T emperature -3 °F {-19.4°C} 7 °F {-13.9°C} 15 °F {-9.4°C} 22 °F {-5.5°C} 29 °F {-1.6°C} 35 °F {1.6[...]

F-1 l A ppendix R TD Resistance Chart Y ou can use the following chart to determine if you need to replace your R TD.[...]

Appendix l G-1 Overhead Plumbing Details Overhead piping installations abo ve process connections require installing a check valv e in the “T o Process” line and a 12 inch {305 mm} riser with a check valv e and vacuum break in the “From Process” line to pre vent siphoning when shutting do wn the chiller . Install a vent tube at 12 inches {3[...]

H-1 l A ppendix Electrical Schematic 9.00 9.00 8.00 8.00 4.04 4.04 1TC 1TC 1ENC 1ENC 1CAB 1CAB 1SW 1SW 2CB 2CB 1CB 1CB 1TB 1TB 1GB 1GB 1 2 2 2 2 3 4 6 7 7 8 9 10 10 2ENC 2ENC 1TC 1TC 1SW 1SW 7.88 7.88 1PL 1PL 2PL 2PL 3PL 3PL 2CAB 2CAB 4PL 4PL 5PL 5PL 7PL 7PL 6PL 6PL[...]

Appendix l I-1 Control Setup 1/32 DIN Watlow SD controller Setup Sheet Enter the following parameters Menu Parameter Description Setting Set Up Page Sen Input sensor type RTD up & down for C-F Temperature Units (degrees) F 3 seconds S.dec Temperature Decimal Places 0 IS.en Infosense no SP.Lo Set Point Low Limit 40.0 SP.hi Set Poing High Limit 6[...]

Plumbing Schematic FROM PROCESS 1 2 " TO PROCESS 1 2 " LEVEL WATE R TA N K 1 PSL FS 1 EVAPORA TOR (1/4" schraeder valve) PI 1 RANGE= 40 T O 65 °F TA H H 1 S TE 1 TA L L TIC 11 S TO PROCESS TEMP (1/4" gauge port) TXV FIL TER/DRYER SIGHT GLASS NOTES: K OR L- TYPE COPPER TUBING TO BE USED FOR REFRIGERANT PIPING 1. PRESSURE TESTING[...]