Conair MPA Operation & User’s Manual
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Conair MPA, All output monitors on the microKool chiller can be enabled or disabled permanently through the OM Enable/Disable Menu in Test Mode. You need to use this feature if you have replaced the mother- board, or if dip switches 7 and 8 have been changed erro- neously. This will enable any required output monitors that were disabled and give fuse failures. Enable Test Mode. Press any key to display the first test menus. Select the OM Enable/Disable menu. Press and hold the Setpoint key for 3 seconds to index to each test menu until the controller indicates “oS1” in the actual display and the status of the selected ou
Conair MPA, The microKool chillers use thermocouples to sense the tem- perature in the return and supply process lines. These thermo- couples should be calibrated annually, or when a new thermo- couple is installed, to ensure correct operation. The chiller’s Calibration Mode provides zero and span calibra- tion of both the supply and return line thermocouples. You access the Calibration Mode while in Test Mode. Enable Test Mode. See P ERFORMING S YSTEM T ESTS . Press any button to display the first test menu. Se
Conair MPA, PREVENTATIVE MAINTENANCE SCHEDULE UGH004/0999 microKool Portable Chillers MAINTENANCE 5-3 ●● Quarterly (every 3 months) ❒❒ Inspect power cords, wires and electrical connections. Check for loose or frayed wires, burned contacts, and signs of overheated wires. Check exterior power cords to the main power source and from the electrical box to the pump and heating elements. Check the ground wire and thermocouple connections. Replace any wire that appears damaged or has worn or cracked insulation. ●● Annually (every 12 months) ❒❒ Test and calibrate the unit’s control systems. The chiller’s Test Mode checks the operation of displays, control buttons, inputs and out
Conair MPA, The chiller process inlets and outlets must be connected to the plumbing that will circulate the temperature-controlled water or fluid through the process. Cooling water inlets and outlets are connected to the cooling water supply. Remove the shipping pipe plug from the female connections on the back of the chiller. Install pipe to the rear of the chiller. Use appropriately sized male NPT piping for the process connections and the MPW condenser water connections. Pipe and pipe threads must be clean and new. Clean threads w
microKool Portable Chillers UGH004/0999 PC-1 microprocessors control the process temperature based upon the average of the temperatures recorded at the supply (to process) and return (from process) thermocouples. The PC-2 microprocessor allows you to select how the unit will measure and control the process temperature. The control point can be selected as the
Conair MPA, 2-1 UGH004/0999 microKool Portable Chillers ●● What is the microKool chiller? .2-2 ●● Typical applications . . . . . . . . . .2-2 ●● How it works: Water-cooled models . . . . . . . .2-3 ●● How it works: Air-cooled models . . . . . . . . . . .2-4 ●● Features . . . . . . . . . . . . . . . . . . .2-5 ●● Specifications: Water-cooled . . .2-6 ●● Specifications: Air-cooled . . . . .2-7 ●● Freeze protection requirements . . . . . . . . . . . . . .2-8 DESCRIPTION
Conair MPA, UGH004/0999 microKool Portable Chiller TROUBLESHOOTING 6-7 SHUT DOWN ALARMS The chiller has detected a problem that could lead to equipment damage or personal injury if it is not corrected. ◆ The Alarm LED lights and the STOP/RUN LED flashes red. ◆ The chiller turns off the compressor, but normal operation resumes after you clear the alarm or the problem corrects itself. ◆ The control displays a red LED or alarm code indicating the source of the problem. Alarm The compressor overload has tripped. NOTE: This alarm is available only on model
Conair MPA, UGH004/0999 microKool Portable Chillers CHANGING TEMPERATURE UNITS The temperature units are factory-set as degrees Celsius or degrees Fahrenheit, as specified when the unit was ordered. When the chiller is on, the indicator lights to the right of the Actual temperature display on the control panel will show which temperature unit has been set. To change this setting, move Dip Switch 1 on the control circuit board. Disconnect and lock out main power to the chiller. Open the electrical enclosure. Change Dip Switch 1 to: OFF for °F ON for °C Close the electrical enclosure and restore main power to begin operating. 12 3 4 5 6 7 8 1 2 3
Conair MPA, You should perform an Auto Tune after the first two hours of operation and whenever process variables change (changes in condenser water pressure, piping or molds; large ambient swings; new setpoint temperature) to ensure that the control continues to obtain good approximations of the PID constants used to compensate for the thermal lag of the system. To ensure a successful Auto Tune, verify that: ❒ The Auto Tune feature has been enabled. Auto Tune is enabled or disabled via dip switch 2 on the motherboard. ❒ The p
Conair MPA, microKool Portable Chillers UGH004/0999 TABLEOF CONTENTS M AINTENANCE . . . . . . . . . . . . . . .(continued) Performing System Tests . . . . . . . . . . . . . . . . . . . . . . . . . .5-7 The Key/Display Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-8 Input Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-9 Output Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-10 Disabling and Enabling Outputs . . . . . . . . . . . . . . . . . . . .5-11 Calibrating Temp
Conair MPA, microKool Portable Chillers UGH004/0999 6-12 TROUBLESHOOTING CHILLER WILL NOT POWER UP If you apply power to the chiller and the control panel does not light, you have a problem with the main power circuit or the unit’s microprocessor board. WARNING: Electrical Shock Hazard Disconnect and lockout the main power supply before proceeding. Symptom Applying power does not turn on the chiller or light the control panel. The control panel is lit, but the chiller will not operate when RUN is pressed. Possible cause Is power reaching the chiller? Has the unit blown a fuse? Is the correct voltage reaching the chiller? Is the unit in
Conair MPA, SHUT DOWN ALARMS microKool Portable Chillers UGH004/0999 6-8 TROUBLESHOOTING Alarm Refrigerant pressure is either too low or too high. WARNING: The microKool should be tested and repaired only by qualified techni- cians equipped with the correct tools and trained in the mainte- nance and repair of electrical and refriger- ant systems used in industrial applications. Possible cause Low refrigerant pressure: Is the refrigerant charge low? Is the liquid refrigerant line restricted? High r efrigerant pressure Has the water or air flow throu
microKool Portable Chillers UGH004/0999 5-6 MAINTENANCE All chillers are fully charged with refrigerant at the factory. Your chiller mode’s nameplate identifies the type and amount of total refrigerant charge required. While the unit is running, check the refriger- ant charge through the sight glass located between the evaporator and the condenser. Use a flash- light to l
Conair MPA, UNPACKING THE BOXES microKool Portable Chillers UGH004/0999 3-2 INSTALLATION Carefully remove the chiller and components from their shipping containers, and set upright. Remove all packing material, protective paper, tape, and plastic. Check inside the electrical enclosure and behind the side panels for accessories or hardware that may have been placed there for shipping. Carefully inspect all components to make sure no damage occurred during shipping, and that you have all the necessary hardware. If damage is found, notify the freight company immediately. Take a moment to record serial numbers and specifications in the blanks provided on the back of the User Guide’s title page.
microKool Portable Chillers UGH004/0999 6-18 TROUBLESHOOTING The freezestat unit is a bulb and capillary thermostat. To replace the unit: Shut down the chiller and disconnect the process fluid lines. Disconnect and lockout the power supply. Drain the tank of all fluid through the drain valve in the base of the tank. Locate the freezestat bulb. The bulb sens
Conair MPA, SPECIFICATIONS: MPW (WATER COOLED) microKool Portable Chillers UGH004/0999 2-6 DESCRIPTION MODEL MPW-1.5 MPW-2 MPW-3 MPW-4 MPW-5 MPW-7.5 MPW-10 Performance characteristics Capacity {tons} * 1.4 1.8 3.1 4.1 4.8 7.6 10.2 Compressor Hp {kW} 1.5 {1.12} 2 {1.49} 3 {2.24} 4 {2.98} 5 {3.73} 7.5 {5.59} 10 {7.45} Pump Hp {kW} † 0.33 {0.246} 0.50 {0.373} 0.75 {0.559} 1.5 {1.12} 1.5 {1.12} 1.5 {1.12} 1.5 {1.12} Chilled water flow gpm {l/min} ‡ 3.4 {12.9} 4.5 {17.0} 7.5 {28.3} 9.9 {37.5} 11.4 {43.2} 18.2 {68.9} 24.5 {81.0} Chilled water pres
Conair MPA, Water-cooled models use tube-in-tube heat exchangers to condense the hot, compressed, refrigerant gas from the compressor to a cool liquid. The cool liquid refrigerant passes through a filter/dryer, which protects the system from moisture or other contami- nants. An in-line sight glass gives a visual indication of proper refrigerant charge and any dangerous moisture pre- sent in the system. The refrigerant passes through a thermal expansion valve, where it expands, cools and is precisely metered into the refrigerant heat exchanger (evaporator). The evaporator removes the heat from the proces
PD-1 UGH004/0999 microKool Portable Chillers ●● PC-1 Wiring Diagram . . . . . . . .PD-2 ●● PC-1 Circuit Board . . . . . . . . .PD-3 ●● PC-2 Wiring Diagram . . . . . . . .PD-4 ●● PC-2 Circuit Board . . . . . . . . .PD-5 ●● Parts Lists . . . . . . . . . . . . . . . .PD-6 PARTS/DIAGRAMS
Conair MPA, 5-1 UGH004/9499 microKool Portable Chillers ●● Maintenance schedule . . . . . . . .5-2 ●● Cleaning evaporators . . . . . . . .5-4 ●● Cleaning condensers . . . . . . . .5-4 ●● Filling the tank . . . . . . . . . . . . .5-5 ●● Checking refrigerant charge . . .5-6 ●● Performing system tests . . . . . .5-7 ●● Key/Display Test . . . . . . . . . . . . .5-8 ●● Input Test . . . . . . . . . . . . . . . . . .5-9 ●● Output Test . . . . . . . . . . . . . . . .5-10 ●●
microKool Portable Chillers UGH004/0999 3-8 INSTALLATION INITIAL SETUP The factory-set parameters and operating modes will satisfy most applications. But you can change some settings and enable or disable features as needed. You can modify the parameters for high and low process tem- perature deviation warnings from the control panel. See S ETTING S ETPOINT D EVIATION P ARAMETE
Conair MPA, microKool Portable Chillers UGH004/0999 6-10 TROUBLESHOOTING WARNING ALARMS Alarm The actual temper- ature of fluid sup- plied to the process is lower than the setpoint deviation limit allows. The actual temper- ature of fluid sup- plied to the process is higher than the setpoint deviation allows. The SPI communi- cation link has failed. Possible cause Is the low deviation tem- perature set too low? Is the low deviation tem- perature set too high? Has the process fluid stopped flowing between outlet and inlet? Is the unloader valve stuck open? Is the unit connected to a host machine? Are the network address and baud rate correc
Conair MPA, UGH004/0999 CHILLER SPI COMMANDS APPENDIX B-3 Status, Machine 1 Poll: 0x21 0x42 SPI STATUS WORD Word BIT position 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0 EEprom error SET SET * A/D converter error SET SET * CJC Error SET SET * RAM hardware SET SET * ROM checksum SET SET * Probe Failure * E/M Hi temp safety SET SET SET * Prog. Hi temp safety SET SET SET * Output monitor failure SET SET * Low water pressure SET SET SET * High deviation alarm * Low deviation alarm * Prog. Lo temp safety SET SET SET * Pump overload SET SET * Refrig. Pressure SET SET * Oil Safety SET SET * Compressor overload SET SET * Freeze Stat SET SET * Low water level SET
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