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MODELS .25A, .33A, .5A, .75A, 1.0A, 1.5A, 2.0A, 3.0A, 5.0A, 7.5A & 10A
MANUAL #O002168 Prepared August 23, 2007 P.O. BOX 5246 TRAVERSE CITY, MICHIGAN 49696 231.946.2931 www.optitemp.com
TABLE OF CONTENTS
INTRODUCTION Unpacking Service/Support SECTION I - Safety Warnings SECTION II - General Information Description Specifications Cooling Capacity Pump Capacity SECTION III Installation & Connection Installation and Connection Electrical Connecting to the Process Drain-back prevention Reservoir SECTION IV - Operation Operating Temperature Range Limits Corrosion Protection Fluid Quality Starting the Unit Refrigeration System Setting the Temperature Controller Setting the PID Parameters SECTION V - Troubleshooting Troubleshooting Guide Preventative Maintenance Checklist SECTION VI - Optional Equipment WARRANTY CERTIFICATION (S) APPENDIX A - Supplemental Information Dew Point/Temperature Chart Filtration General System Specifications Control Parameters General Install Schematic (If Applicable) Electrical Schematic Equipment Options Control Parameter Manual 2 2
4 4 4 4
5 5 6 7 7
8 8 8 9 10 10 11
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INTRODUCTION
Thank you for choosing OPTI TEMP for your heat transfer needs. OPTI TEMP welcomes your comments and feedback. Please feel free to contact us with any questions, comments, concerns, or feedback you may have regarding the OPTI TEMP unit or this manual. Unpacking Before accepting the unit from the freight company, visually inspect the unit for any shipping damage. If there is any indication that the package was mishandled, further inspection should be done immediately in front of the delivery driver. Note all visual damage on the delivery receipt prior to acceptance. Remove the unit from the package and again inspect for any damage that could have occurred during shipment. If damage is noted, be sure to file a claim IMMEDIATELY with the carrier. Remove any packing materials and support materials from the unit. NOTICE IN ORDER TO PROTECT THE UNIT FROM FREEZING WHEN SHIPPED DURING THE WINTER SEASON (GENERALLY BETWEEN OCTOBER 1st and APRIL 30th), THE UNIT MAY BE SHIPPED WITH A SMALL AMOUNT OF ANTIFREEZE IN THE RESERVOIR AND PUMP. YOU MAY WANT TO FLUSH THIS ANTIFREEZE OUT OF THE SYSTEM BEFORE CONNECTING TO YOUR SYSTEM. The amount of anti-freeze used is very small. Contact OPTI TEMP at 231.946.2931 with disposal concerns. If the unit is not equipped with casters, there may be rubber pads or feet in a plastic bag attached to the electrical cord. If provided, you should install the feet on the four corners of the unit, using the double-sided tape that is included in the plastic bag for this purpose, If the unit must be lifted, utilize a forklift. Place the forks evenly across the bottom for proper support and balance. Service/Support Opti Temp is committed to customer service both during and after the sale. If you have questions concerning the unit operation, please contact our Service Department at 231.946.2931. OPTI TEMP systems are built to provide years of trouble free service. All systems are tested prior to shipping to insure you receive the highest quality product. In the unlikely event you experience problems, rest assured our technical service staff will be available to assist you resolve any problems quickly. If your unit fails to operate properly, or if you have questions concerning spare parts or Service, contact our Service Department at 231.946.2931. Before calling, please refer to the serial number tag to obtain the serial number: -Unit Serial Number ___________________________________
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SECTION 1: SAFETY
Warnings
Warnings can be found throughout the manual. These warnings are designated by an exclamation mark inside a yellow triangle and text highlighted in bold. Failure to observe these instructions can result in permanent damage to the unit, significant property damage, or personal injury or death. Make sure you read and understand all instructions and safety precautions listed in this manual before installing or operating your unit. If you have any questions concerning the operation of your unit or the information in this manual, please contact our Sales Department (see service/support). 1. 2. 3. For safety reasons power supplies must be properly grounded. All Federal, state, and local codes should be followed. Never use flammable or corrosive fluids with this unit. Do not use automobile anti-freeze. Automotive anti-freeze often contains silicates or other components that can damage your system. Only an un-inhibited ethylene glycol should be used. Use of automobile anti-freeze will void the manufacturers warranty. Never place the unit in a location where excessive heat, moisture, or corrosive materials are present. Do not modify or seal reservoir in any way. Performance of installation, operation, or maintenance procedures other than described in this manual may result in a hazardous situation and may void the manufacturers warranty. Transport the unit with care. Sudden jolts or drops can damage internal components. Observe all warning labels. Never remove warning labels. Never operate damaged or leaking equipment. Never operate the unit without heat transfer fluid in the reservoir. Always disconnect power to the unit before opening the control box. Always empty the reservoir before moving the unit. Never operate equipment with damaged power cords. Refer service and repairs to a qualified technician.
This manual assumes the OPERATOR is non-technical with limited training and the RESPONSIBLE BODY is technical and fully trained. Your equipment contains refrigerant within its cooling system. The refrigerant is designated as a florinated greenhouse gas. The specific type and quantity of refrigerant contained within the refrigeration system is listed on the units serial tag. The Global Warming Potential (GWP) of the refrigerants used by Opti Temp is:
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The following Operation Manual Information is based on Standard Opti Temp Inc. units. For custom units, please refer to the appendix for special instruction sheets.
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Operating/Ambient Conditions: i. Operating Temperature Range: 7 to +40oC (+45 to 104oF). ii. Storage Temperature: -10 to +55oC (+14 to 131oF) iii. Operating Ambient Humidity Conditions: 0 to 90 % relative humidity up to 40oC (non-condensing), 10 to 50% relative humidity from 40 to 55oC (non-condensing). Electrical
CAUTION (REFER TO ACCOMPANYING DOCUMENTS) CAUTION: RISK OF ELECTRICAL SHOCK. DISCONNECT SWITCH REQUIRED TO DE-ENERGIZE THE EQUIPMENT BEFORE SERVICING. Refer to the section II, Specifications, Appendix A, and the serial number tag for the specific electrical requirements of your unit. Bring adequate electrical power to the unit. Ensure the voltage of the power source meets the specified voltage, +/- 10%. This power must be through a circuit breaker or a switch-able fused disconnect that is in close proximity to the unit and within easy reach of the operator. Be sure that the unit is grounded, (and the disconnect does not remove the ground). See specifications for 50 Hz operation.
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OPTI TEMP systems are equipped with a compressor crankcase heater. The heater warms the oil in the compressor and will separate refrigerant mixed with the oil. Before starting the unit in a cold environment, be sure that power is applied to the unit for a minimum of 12 hours or serious system damage may result. Connecting to the Process Standard stainless steel fittings are provided on the OPTI TEMP unit for connecting TO and FROM process lines. NOTE: All fittings are a male NPT nipple. Run next size larger hose (see data sheet) to and from your process. It is suggested that a valve be installed on the TO PROCESS line and FROM PROCESS line at the OPTI TEMP unit, to be used as balancing valves to balance the flow to the process or as an isolation valve should maintenance be required on the unit. CAUTION: THE FITTINGS ARE CONNECTED TO A MANIFOLD PLATE ATTACHED TO THE UNIT. DO NOT OVERTIGHTEN FITTINGS SUCH THAT YOU BREAK THE FITTINGS FROM THE MANIFOLD PLATE
Never connect the fittings to your building water supply or any pressurized water source.
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Drain Back Prevention Depending on the length of hoses and thus the amount of fluid contained in the system, some fluid may drain back causing the reservoir to overflow when the unit is turned off during shut down periods. The drain back would normally be minimal unless there is a leak in the system. If this occurs and provision cannot be made in the reservoir to handle the drain back, the problem can be eliminated by locating the unit so the reservoir is at the same level or above the system; or a check valve can be installed in the process supply line and a solenoid valve installed in the process return line to prevent drain back. Call the factory if this is a problem, or for further information. Reservoir
The OPTI TEMP system is designed as an open system with the top of the reservoir at atmospheric pressure. Do not connect any fittings to the cover of the reservoir or pressurize the reservoir in any way or damage to the system and or personal injury could result. The reservoir is designed to be filled manually.
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OPTI TEMP systems are designed to operate within a certain specified temperature range. All systems are not designed to operate over the same range. It is important that you do not operate the system outside of this intended range. Please refer to the specifications in APPENDIX A for the operating range of your system.
If this is a low temperature unit, DO NOT OPERATE ABOVE 110oF (40oC). If this is a high temperature unit, DO NOT OPERATE ABOVE 190oF (90oC).
DO NOT OPERATE UNIT ABOVE this temperature range. System damage and/or personal injury may result. Corrosion Protection / Fluid Quality Generally, OPTI TEMP recommends the use of distilled or de-ionized water with its systems instead of tap water because tap water can have a high level of total ionized solids, which can accelerate corrosion. These contaminants function as electrolytes, which increase the potential for galvanic corrosion. Tap water in the US averages 175 ppm (NaCl). The recommended level is between 0.5 to 5 ppm. Normally OPTI TEMP recommends that systems, which require a fluid conductivity below 240 microsiemans/cm, utilize stainless steel construction. Systems where conductivities are permitted to be above 240 microsiemans/cm may use OPTISHIELD corrosion inhibitor to control corrosion and extend system life. OPTI TEMP provides a corrosion inhibitor called OPTISHIELD, which provides protection from corrosion resulting from the presence of dissimilar metals in the cooling circuit. You may wish to use OPTISHIELD Corrosion Inhibitor to protect the OPTI TEMP unit and your process from corrosion. Check with the engineers at OPTI TEMP INC and your machinery supplier for further information. Contact OPTI TEMP or your Process Manufacturer for more information regarding system water quality and corrosion inhibitors.
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Starting the Unit Fill the reservoir to within 2 (50mm) from the top of the reservoir or fill port (OR AS NOTED ON THE SIGHT GLASS IF PROVIDED) with the proper heat transfer fluid. Turn on the unit and press the START button. There is a float switch in the unit that will turn on the PUMP ALARM light and stop the unit if the fluid level falls below a safe level. If this happens, turn the unit off and fill the unit again with clean fluid. Repeat this procedure until the system is filled. NOTE: Check pump rotation on 3 phase units at this time. Follow the instructions on the power cord tag. It is recommended that the unit be allowed to run for a few minutes before the reservoir is completely filled. This allows the air to bleed from the lines more easily. Vent the air out of the system. It is helpful to open a valve or a fitting at the system high point (while the system is running) and bleed the air until fluid starts to flow, then close the valve or retighten the fitting. There is an automatic pressure actuated bypass valve in the unit to bypass fluid around the process and back into the Opti Temp reservoir if flow to the process is interrupted for any reason. It is normally factory set at 80 PSI (60 PSI on 2-30A). Adjustment at your facility may be necessary depending on the process requirements. Adjust the bypass valve by: 1. 2. 3. 4. 5. Remove cap (if applicable) Loosening the locking ring with pliers. Lower the pressure by turning the adjustment knob counter-clockwise. Tighten the locking ring with pliers so that it cannot be turned by hand. Replace cap (if applicable)
PLEASE CONTACT OPTI TEMP IF YOUR PROCESS IS EQUIPPED WITH A VALVE, WHICH MAY OR PERODICALLY INTERRUPT FLOW TO THE PROCESS. BYPASS SETTINGS MAY BE CRITICAL TO PROTECT THE SYSTEM FROM DAMAGE! It is recommended that the valve in the supply line to the process be throttled (closed slowly) until the bypass valve just starts to feed. By putting your hand on the valve and bypass line you will be able to feel when the valve starts to open. This allows the air to be cleared from the bypass line. Again check to be sure the fluid in the reservoir is at the proper level. The float switches should be floating. The fluid level in the unit should be checked at least once a week to insure there is adequate fluid in the unit. NOTE: IF THE UNIT IS USED IN A MANNER NOT SPECIFIED BY OPTI TEMP INC., THE PROTECTION PROVIDED BY THE EQUIPMENT MAY BE IMPAIRED
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Refrigeration System Your OPTI TEMP unit uses refrigerant components including compressors, expansion valves and heat exchangers to cool the process supply fluid. WHEN THE OPTI TEMP UNIT IS STARTED COMPRESSOR WILL AUTOMATICALLY START. THE REFRIGERATION
The system is designed such that the compressor will continue to run at all times during the OPTI TEMP units operation. The controller will modulate the quantity of refrigerant used for cooling dependent on the process cooling load. Setting the Temperature Controller This section will discuss the basic control operation and the basic settings. For more complete instruction on the operation of the controller and available options, please read the Instruction Manual for the controller included with this manual. There are two digital display windows on the temperature controller. The upper window displays the actual temperature of the fluid going to the process or the PROCESS VALUE. The lower window displays the SET VALUE of the controller. To the Left of the Upper window there is a small SP1 that will light if the unit is in the cooling mode (the TXV solenoid valve is in the open position). There are several lights over the PROCESS VALUE window on the controller. For CHILLERS (OTC) the AL light stands for alarm and is the freeze alarm for the unit. This has been set at the factory to light if the process temperature falls too low (see Control Parameter Settings Sheet in the Appendix). It will also light the larger freeze alarm light on the panel and shut off the refrigeration system (the compressor and fans). The pump will remain in operation. It will sound the audible alarm (if provided with the unit). If you wish to run at a temperature below the normal setting, see the Trouble Shooting Section Unit Shuts Off---Freeze Alarm Light Is On. On CHEATERS (OTR) the AL light stands for alarm and is the LIV set point for the unit. This has been set at the factory to activate if the process temperature falls to the AL1 set point (see Control Parameters page). To change the temperature set value, it is necessary to touch INDEX (the keypad on the far left) once. SP1 will appear in the lower window and the current set point will appear in the upper window. Touch the UP ARROW to raise the set point, or the DOWN ARROW to lower the set point to the desired set point temperature. When the desired temperature appears in the upper window, press ENTER (the keypad to the far right) to store the new temperature.
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IT IS NECESSARY TO TOUCH THE ENTER KEYPAD TO INPUT THE NEW TEMPERATURE. Touch the INDEX keypad again and SP2 will appear in the lower window, and its setting (see Control Parameter Settings Sheet in the Appendix) will appear in the upper window. Touch the INDEX keypad again to return to the operating mode with the Set Point in the lower window and the Process Value in the upper window. Setting the PID Parameters This temperature controller is arranged to provide PID temperature control. PID stands for Proportional-Integral-Derivative control, and for most load situations will give the process more stable temperature control than On/Off control. Under PID control, the temperature controller anticipates cooling and heating requirements and will institute these control activities in anticipation of the load requirements to give more stable temperature control to the process. This temperature controllers PID constants are preset at the factory. This is described on page 22 of the manual. This temperature controller is equipped with Fuzzy Logic. Fuzzy Logic maintains better temperature stability under changing load conditions and allows the unit to come to temperature stability faster after temperature changes. It is important to note that THE FUZZY LOGIC FEATURE OF THIS CONTROLLER IS ENGAGED, AND WE RECOMMEND THAT IT REMAIN ENGAGED. With the fuzzy logic, the unit will provide better temperature stability than when it is not engaged. For more information on these features, please see the Temperature Controller manual in Appendix A. If the optional audible alarm is purchased with the unit, it will be mounted on the control box and both the red light will light and the alarm will sound if a low fluid level condition occurs. The unit will now run and cool the laser, or process.
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Section V: Troubleshooting
CAUTION:
RISK OF ELECTRICAL SHOCK. DISCONNECT SWITCH REQUIRED TO DE-ENERGIZE THE EQUIPMENT BEFORE SERVICING. ALWAYS DISCONNECT POWER TO THE UNIT BEFORE OPENING CONTROL BOX. The following Troubleshooting guide is based on Standard Opti Temp Inc. units. For custom units, please refer to the appendix for special instruction sheets. UNIT SHUTS OFF The unit will go off on alarm and the RED alarm light will come on if the reservoir fluid level drops too low. Turn the unit off, remove the fill port cap and check the fluid level. If it is too low, add fluid (as described above), turn on the unit. If the unit still does not start, and you have verified that the unit has adequate fluid in the reservoir and is within the proper range, contact OPTI TEMP INC. at the number located in the Service/Support Section II. LOSS OF CAPACITY NOTE: IF THE UNIT EXHIBITS A LOSS IN CAPACITY, CHECK THE CONDENSER (THE FINNED TUBE COIL) FOR CLEANLINESS. VACUUM OR USE COMPRESSED AIR TO BLOW OUT THIS COIL OR A POWER WASHER TO CLEAN THE COIL. IF A POWER WASHER IS USED, BE SURE TO PROTECT THE ELECTRICAL COMPONENTS FROM WATER. If the OPTI TEMP unit still exhibits a loss in capacity; you observe the compressor is not running or any other refrigeration related problem occurs, we suggest calling a refrigeration service technician. The unit is equipped with sight-glass and access ports to enhance quick troubleshooting and minimize any potential down time. Of course OPTI TEMP is available to assist with trouble you may have. See Service/Support in Section II. UNIT NOT HOLDING SET TEMPERATURE (TEMPERATURE GOES TOO HIGH) Check the load on the unit compared to the cooling capacity of the unit. If the unit is over loaded it will not hold the temperature setting. Check to be sure that the cooling solenoid valve is functioning properly. When cooling is required, the SP1 light will light on the temperature controller and you will hear a definite click when the solenoid valve opens and closes. If you do not hear this click when the unit calls for cooling, the solenoid is either not getting power to open (an electrical fault) or the solenoid is faulty.
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If the unit still does not function properly, contact OPTI TEMP INC. at 231.946.2931. UNIT NOT HOLDING TEMPERATURE (TEMPERATURE GOES TOO LOW) Have the RESPONSIBLE BODY check to be sure the cooling solenoid is not stuck open allowing refrigerant to enter the refrigerant / cooling water heat exchanger. The expansion valve after the solenoid should be cool to the touch but not cooler than the supply water to the chiller. If the expansion valve is cold and a vibration or noise (rushing liquid) can be heard at the solenoid and expansion valve, ensure there is no electrical power going to the solenoid. If there is no voltage at the solenoid electrical coil, then the valve is stuck open and a refrigeration service technician should be called to replace the valve. If you need additional help, contact OPTI TEMP INC. at 231.946.2931. TEMPERATURE OF THE RESERVOIR IS NOT THE SAME AS INDICATED ON THE CONTROLLER There will always be a slight difference between the controller indicated temperature and the temperature measured in the reservoir. Also, one must be sure that the thermometer used to measure the reservoir temperature is accurate. One should use two thermometers that read the same to confirm the accuracy of the thermometers used. One must also measure the reservoir temperature as close to the end of the thermocouple that is in the reservoir as possible. If the temperature difference seems too high, the controller is probably out of calibration or the unit has a faulty thermocouple. The controller can be calibrated by adjusting the InPC (or InC1) function on the secondary menu of the controller. See the temperature controller manual or contact the factory for further details. You can reach OPTI TEMP INC. at the number located in the Service/Support Section II. TEMPERATURE CONTROLLER IS READING OPEn InP or OPEn This generally indicates a sensor failure. Have the RESPONSIBLE BODY turn off the unit and unplug the unit. Open the control panel door and check to be sure that the red thermocouple lead is connected tightly to terminal 3 of the controller and the white (or yellow) thermocouple lead is connected tightly to terminal 1 of the controller (see the electrical schematic in this control manual). Plug the unit in and start the unit. If this does not correct the problem, contact OPTI TEMP INC. at the number located in the Service/Support Section II.
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COMPRESSOR SHUTS OFFFREEZE ALARM LIGHT IS ON AND CONTACTS OPEN The standard freeze alarm setting is 45oF (7oC). It will light the (optional) freeze alarm light on the panel and shut off the refrigeration system (the compressor and fans). The pump will remain in operation. It will sound the audible alarm (if provided with the unit). This is done so that someone wont inadvertently set the temperature below freezing without adding antifreeze to the system. If you wish to run below 45oF (7oC), ADD AN INDUSTRIAL ETHYLENE GLYCOL OR PROPYLENE GLYCOL TO THE SYSTEM. DO NOT USE AUTOMOTIVE ANTIFREEZE. Use the glycol manufacturers recommended concentration for 6oC BELOW your desired operating temperature and install this percentage of glycol into the system. Please keep in mind that glycols reduce the heat transfer efficiency of the heat exchange components in the system. Your unit will have less capacity when using glycols . BE SURE YOU INSTALL ENOUGH ANTIFREEZE TO PROTECT TO 6oC BELOW YOUR DESIRED OPERATING TEMPERATURE. DAMAGE TO YOUR OPTI TEMP CHILLER DUE TO FREEZING FOR ANY REASON IS NOT COVERED BY WARRANTY! If you wish to operate unit below 7oC(45oF), contact OPTI TEMP INC. at 231.946.2931. If the F2 control fuse blows, have a qualified electrician or the responsible party inspect for problems. The replacement fuse for F2 is a Amp (2.5 Amp on 15A30A Units), type F fuse.
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PREVENTATIVE MAINTENANCE CHECKLIST WEEKLY CHECKS: Confirm the proper fluid level in the tank and add fluid if necessary. (OPERATOR) QUARTERLY CHECKS: Check the condenser and fan blades and clean if necessary. (RESPONSIBLE BODY)