Accuchiller

AQ Series
Air and Water Cooled
Operation and Installation Manual
Thermal Care, Inc.
7720 N. Lehigh Ave.
Niles, IL 60714-3491
Phone
Fax
E-mail
Website

(847) 966-2260
(847) 966-9358
info@thermalcare.com
www.thermalcare.com

Customer Service
Phone
(847) 966-2636
Fax
(847) 966-2906
Parts
Phone
Fax

(847) 966-8560
(847) 966-6065

TABLE OF CONTENTS
Page No.
Foreword
3
Pre-Installation
5
Receiving Inspection
5
Rigging, Handling & Locating Equipment
5
Installation
7
Electrical Power
7
Air Cooled Condenser (Air Cooled Chillers Only)
7
8
Condenser Water Lines (Water Cooled Chillers Only)
Required Condenser Water Flow Table
9
Chilled Water Lines
9
Suggested Chilled Water Flow Table
10
Suggested Pipe Sizing Table
11
Overhead Piping Diagram
11
Chiller Start-Up
12
Recommended Glycol Mixtures Table
13
Control Panel Operation
15
Control Panel Diagram
15
Microprocessor Control Fault Logic Table
15
Control Buttons
16
Diagnostic LEDs
18
Diagnostic Error Codes
21
Control Options
22
Chiller Operation
26
Typical Piping Schematic Diagram
26
Coolant Circuit
27
Refrigerant Circuit
28
Chiller Construction
30
Refrigeration Components
30
Wet-Side Components
34
Operating and Safety Controls
36
Standard Options
38
Preventive Maintenance
40
Preventive Maintenance Checklist
42
Troubleshooting
43
Pump Curves
47
Diagrams
48
AQ0A0H Wiring Diagram
48
AQ0A01 Wiring Diagram
49
AQ0A02 - AQ0A10 Wiring Diagram
50
AQ0W02 - AQ0W05 Wiring Diagram
51
AQ0W08 - AQ0W10 Wiring Diagram
52
AQ1W05 - AQ1W15 Wiring Diagram
53
AQ1W20 - AQ1W30 Wiring Diagram
54
AQ1W35 - AQ1W40 Wiring Diagram
55
Air Cooled Dimensions
56
Page 2 Cooled Dimensions
Water
57
Warranty
58

FOREWORD
The intent of this manual is to serve as a guide for placing your portable chiller in service, and operating and maintaining it properly.
This manual will be supplemented as required to accommodate any
special items which may have been provided for a specific application.
The written information contained in this manual, as well as
various drawings, are intended to be general in nature. The
schematics included in this manual are typical only. Actual schematics are included in the electrical enclosure of the chiller and should be
referred to for troubleshooting and servicing of the unit. Additional
copies of wiring diagrams are available upon request. We strive to
maintain an accurate record of all equipment during the course of its
useful life. While every effort is made to standardize the design
features of these chillers, the various options may make it necessary
to rearrange some of the components; therefore, some of the general
drawings in this manual may differ from your specific unit.
Specific references to current applicable codes, ordinances, and other
local laws pertaining to the use and operation of this equipment are
avoided due to their ever changing nature. There is no substitute for
common sense and good operating practices when placing any mechanical equipment into operation. We encourage all personnel to
familiarize themselves with this manuals contents. Failure to do so
may unnecessarily prolong equipment down time.
Our chilling equipment uses chemical refrigerants for heat transfer
purposes. This chemical is sealed and tested in a pressurized system
containing ASME coded vessels; however, refrigerant gas can be
released if there is a system failure. Refrigerant gas can cause toxic
fumes if it is exposed to fire. These units must be placed in a well
ventilated area, especially if open flames are present. Failure to
follow these instructions could result in a hazardous condition.
The standard refrigerant used in these units is a hydrochloro-fluorocarbon (HCFC) trade named R-22. The EPA has enacted laws regarding the handling of refrigerants and eventual phaseout of HCFC
refrigerants. HCFC refrigerant production will continue until January 1, 2010 for new equipment and until January 1, 2020 for service
purposes. Customers are advised to immediately implement a refrigerant management program including a survey of all equipment to
document the type and quantity of refrigerant in each machine. All
refrigeration service technicians must be certified by an EPA approved organization.

Page 3

It is recommended that good piping practices are followed and that

the information in this manual is adhered to. We cannot be held
responsible for liabilities created by substandard piping methods and
installation practices external to the chiller.
We trust your equipment will have a long and useful life. If you
should have any questions, please contact our Customer Service
Department specifying the serial number and model number of the
unit as indicated on the nameplate.

Page 4

PRE-INSTALLATION
Receiving Inspection
Each unit is skid mounted and either boxed or crated prior to shipment. Before accepting delivery, check the overall equipment condition for any visible damage. If damage is evident, it should be properly documented on the delivery receipt. Shipping damage is the
responsibility of the carrier. In order to expedite payment for damages, it is important that proper procedures be followed and records
kept. Photographs of damaged equipment are excellent for your
records.
Once the unit is removed from the box or crate, it should be inspected
for hidden damage. Refrigerant lines can be susceptible to damage in
transit. Check for broken lines, oil leaks, damaged controls, or any
other major component torn loose from its mounting point.
Note: Any sign of damage should be recorded and a claim filed
immediately with the shipping company. We will provide assistance in preparation and filing of your claims, including arranging for an estimate and quotation on repairs; however,
filing the claim is the responsibility of the receiving party.

Rigging, Handling, and Locating Equipment

The units have a base platform on casters (two fixed and two swivel)
to provide in-plant mobility. Proper rigging methods must be followed
to prevent damage to components. Avoid impact loading caused by
sudden jerking when lifting or lowering the chiller. Use pads where
abrasive surface contact is anticipated. The skid supporting the
chiller can be used for positioning the unit with a fork lift.
As standard, these chillers are designed with NEMA-1 construction
suitable for indoor use. Unless this unit was specifically ordered with
NEMA-4 construction for outdoor duty, it should not be installed or
even stored in an outdoor location.
Serviceability was a primary concern when designing your portable
chiller. Removable panels permit easy access for periodic maintenance or repair. Do not compromise this feature by locating the chiller
in an inaccessible area.

Page 5

! Air Cooled Chillers

In order to accommodate the air cooled condenser, the chiller must be
located in a well ventilated area. A minimum of three feet of clearance is required at both the condenser air inlet and condenser air
discharge. Improper clearance or poor ventilation will reduce the
cooling capacity of the chiller and may cause high refrigerant pressure
problems. The condenser air inlet temperature should be maintained
above 60F (15C) in order to avoid possible low refrigerant pressure
safety trips during start-up.
If it is necessary to store the chiller in an unheated area when not in
use, be sure that all water is drained or that an adequate amount of
antifreeze is added to prevent freeze-up of the unit.

! Ethylene Glycol

Warning: Ethylene glycol is harmful or fatal if swallowed

or inhaled. Do not drink ethylene glycol solution. If
swallowed, give two glasses of water and induce vomiting.
Call a physician immediately. Avoid inhaling mist or hot
vapors. If inhaled remove to fresh air. Do not store in
open or unlabeled containers. Wash thoroughly after
handling. Solution can be poisonous to animals.

! Propylene Glycol

Page 6

Warning: Although propylene glycol is not "toxic," as

defined by regulations of the Consumer Product Safety
Commission, it is not intended for human or animal
consumption.

INSTALLATION
Electrical Power
Note: Main power to the chiller should remain connected during off hours to energize the compressor's crankcase heater.
Disconnect main power only when servicing the chiller. The
crankcase heater should remain on at all times to ensure
liquid refrigerant does not accumulate in the compressor
crankcase.

A terminal block is provided for main power connection to the electric

circuitry. An electrical knockout in the back panel for 1/2" conduit has
been provided for main power wiring. This knockout may have to be
enlarged for chillers with higher amp draws. All components requiring electric power are prewired at the factory. The main power source
should be connected to the terminal block through an appropriate
disconnect switch. A separate lug for grounding the unit is also provided in the main control panel.
Note: All chillers should be properly grounded in compliance
with local and national codes.

The control panel and safeties are interwired such that connecting the
appropriate power source to the main terminal block energizes the
entire electric circuitry of a chiller. A control transformer has been
factory wired to step down the incoming power to the 115 volt control
power.
Note: Electric power at the main disconnect should be shut off
before opening access panels for repair or maintenance.

Air Cooled Condenser (Air Cooled Chillers Only)

The performance of an air cooled condenser is dependent upon maintaining the proper flow of air across the heat exchanger surface. If the
air flow is restricted at either the intake or discharge, the cooling
capacity of the chiller will be reduced. Reduced air flow may also
result in high refrigerant pressure problems which will cause the
chiller to shut down. Air flow can also be reduced if the condenser
coils become clogged with dirt. For this reason, try to avoid locating
the air intake where foreign matter is likely to be drawn through the
condenser. If the condenser does become clogged, it can be cleaned out
using compressed air.

Page 7

The standard rated cooling capacity of our air cooled chiller is based
upon 95F (35C) ambient air temperature. If the air temperature
entering the condenser is above 95F (35C), the capacity will be
reduced approximately 1% per 1F (0.5C). Entering air temperatures
above 110F (43C) may result in high refrigerant pressure problems
which would shut the unit down. For this reason, it is very important
that the chiller be located where the warm discharge air will not be
recirculated back into the condenser inlet.
These chillers are designed for indoor usage with normal indoor
ambient air temperature entering the condenser. Air temperatures
below 60F (15C) entering the condenser may result in low refrigeration pressure "cold start-up" problems.

Note: The condenser fans on these chillers are designed to pull

the air through the condenser and discharge it out the side of
the unit. Ductwork should not be installed on the intake or
discharge of these units.

Condenser Water Lines (Water Cooled Chillers Only)

The performance of the water cooled condenser is dependent on maintaining the proper flow and temperature of water through the heat
exchanger. Insufficient water flow or high condenser water supply
temperature will result in the reduction of cooling capacity of the
chiller. Extreme conditions will eventually result in the chiller shutting down due to high refrigerant pressure. Performance can also be
affected if the condenser is allowed to plug up from contaminants in
the condenser water stream. In order to reduce maintenance costs
and chiller downtime, a water treatment program is highly recommended for the condenser cooling water.
If the condenser does become plugged, contact our Customer Service
Department for assistance in the proper procedure for cleaning out
the condenser.
The standard rated cooling capacity of a water cooled portable chiller
is based upon 85F (29C) condenser cooling water supply. With 85F
(29C) condenser water supply, approximately 3 GPM of condenser
water will be required per nominal ton of chilling capacity. There
should be a minimum of 25 PSI differential between the condenser
water supply pressure and the back-pressure on the outlet of the
condenser. If the chiller has been equipped with a condenser water
regulating valve, the condenser water flow will be regulated to mainPage 8

tain the refrigerant pressure at the factory set level. The condenser
water regulating valve is standard on models AQ0W02 through
AQ1W15 and optional on all other models. The following chart shows
condenser water requirements and pipe sizing for the different size
chillers. Please note that a condenser water supply temperature
below 75F (24C) will not necessarily result in reduced flow
requirements.

Required Condenser Water Flow

Model #
AQ0W02
AQ0W03
AQ0W05
AQ0W08
AQ0W10
AQ1W15
AQ1W20
AQ1W25
AQ1W30
AQ1W35
AQ1W40

75F (24C) 85F (29C)

Condenser Condenser
Water
Water
Flow
Flow
(GPM)
(GPM)
3
5
4
8
8
15
12
24
16
31
22
44
29
57
34
68
40
79
50
100
60
120

Condenser
Water
Connection
(FNPT)
1"
1"
1"
1"
1 1/2"
2"
2"
2 1/2"
2 1/2"
2 1/2"
3"

Chilled Water Lines

All chilled water piping should be adequately insulated to prevent
condensation. If water is allowed to condense on the piping, the state
change of the water from gas to liquid will result in a substantial heat
load which becomes an additional burden for the chiller.
Standard portable chillers have been designed for a nominal flow of
2.4 GPM per ton at nominal conditions. During normal full-load
operation with 50F (10C) coolant supplied to the process, this nominal flow rate will result in a 60F (15C) coolant returned from the
process. The nominal flow rate for each chiller is shown in the Suggested Chilled Water Flow table. This table also provides the maximum flow rate for each chiller. The maximum flow rate should not be
exceeded unless the chiller was specifically ordered to handle highflow conditions.
If the process cannot handle the full nominal flow from the chiller, the
excess water flow will simply bypass the process through the bypass
line inside the chiller. On air cooled models AQ0A0H through AQ0A03
Page 9

and water cooled models AQ0W02 through AQ0W05, the bypass line is
fixed and requires no adjustment. On air cooled models AQ0A06
through AQ0A10 and water cooled models AQ0W08 through AQ1W40,
there is a cock valve on the bypass line which may require adjustment
if the chiller is not operated using the nominal flow rate. This valve is
located where the bypass line enters the reservoir.

Suggested Chilled Water Flow

Model #
AQ0A0H
AQ0A01
AQ0A02
AQ0A03
AQ0A06
AQ0A08
AQ0A10
AQ0W02
AQ0W03
AQ0W05
AQ0W08
AQ0W10
AQ1W15
AQ1W20
AQ1W25
AQ1W30
AQ1W35
AQ1W40

Nominal
Flow
Rate
(GPM)*
1
2
4
7
12
16
20
5
8
12
19
25
40
46
54
63
80
96

Maximum
Flow
Rate
(GPM)*
2
4
8
14
24
32
40
10
16
24
38
50
80
92
108
126
160
160

*A throttling valve on the process supply

line is provided to adjust the flow rate to
process.

Page 10

The importance of properly sized piping between the chiller and

process cannot be overemphasized. See the Suggested Pipe Sizing
table for proper pipe sizing. In general, run full size piping out to the
process and then reduce the pipe size to match the connections on the
process equipment. One of the most common causes of unsatisfactory
chiller performance is poorly designed piping. Avoid unnecessarily
long lengths of hoses or quick disconnect fittings which offer high
resistance to water flow. When manifolds are required for water
distribution, they should be installed as close to the use point as
possible. Provide flow balancing valves at each machine to assure
adequate water distribution in the entire system. Typically, when
piping is overhead with a total length of 90' or more, place a check
valve in the supply line and trap the return line (see Overhead Piping
Diagram).

Suggested Pipe Sizing

Pipe
Size
1/2"
3/4"
1"
1 1/4"
1 1/2"
2"
2 1/2"
3"

Maximum
Flow Rate
(GPM)*
2
5
10
20
30
50
90
160

*Based on standard
weight schedule 40 black
iron or PVC schedule 80
pipes.

Overhead Piping

SPA-0121

Page 11

CHILLER START-UP
All chillers are fully tested prior to shipping. Readings of voltage,
amperage, compressor suction and discharge pressures, water inlet
and outlet temperatures, water flow rates, etc., are recorded to make
sure that all system components are performing up to their specifications. Every unit is factory set to deliver chilled water in accordance
with the standard operating specifications for that particular chiller.
Due to variables involved with different applications and different
installations, minor adjustments may be required during the initial
start-up to ensure proper operation.
The following start-up procedure should be followed in sequence. If
trouble is encountered in putting a chiller in operation, the fault can
usually be traced to one of the control or safety devices. This outline
can be used as a checklist for the initial start-up and for subsequent
start-ups if the chiller is taken out of service for a prolonged period of
time.
1. Assure the main power source is connected properly and that it
matches the voltage shown on the nameplate of the unit. Once
proper power connection and grounding have been confirmed, turn
the main power on.

Note: The power must be on for 24 hours prior to starting the

compressor to allow the crankcase heater to sufficiently
vaporize any liquid refrigerant that may be present in the
compressor.
2. Check to make sure that all process chilled water piping connections are secure. Remove the top panel from the chiller and the
screw cap from the top of the reservoir. Fill the reservoir with the
proper water or water/glycol solution.
3. (Water Cooled Units Only) Check the condenser water lines to
make sure all connections are secure. Make sure sufficient condenser water flow and pressure are available (see Required Condenser Water Flow table), that the condenser water supply is
turned on, and that all shut-off valves are opened.
4. Check to make sure that all process chilled water piping connections are secure. Remove the top panel from the chiller and the
screw cap from the top of the reservoir. (On the AQ1W35 and
AQ1W40, use the fill port that extends through the top of the
cabinet.) Fill the reservoir with the proper water or water/glycol
solution.

Page 12

Recommended Glycol Mixtures

Percent
Chilled Water Glycol by
Temperature
Volume
50F (10C) not required
40F (4.4C)
20%
30F (-1.1C)
20%
20F (-6.6C)
25%
10F (-12.2C)
35%
0F (-17.7C)
40%

Note: Water quality can vary greatly in different areas of the

country. Some water may require water treatment chemicals.
A corrosion inhibitor can be added if necessary; however, make
sure that it is compatible with ethylene glycol if there is glycol
in the system.

5. Make sure that the Freezestat is set appropriately for the operating conditions of the chiller. The Freezestat is located inside the
main electrical control panel. It should be set at 10F (5C) below
the minimum chilled water temperature setting that the chiller
will be operated at. Be sure that there is sufficient glycol in the
system to handle at least 10F (5C) below the freezestat setting.
All chillers are shipped from the factory with the Freezestat set at
40F (4C). This is done to protect against a possible freeze-up if
no glycol has been added to the system. Once the proper glycol
solution has been added, the freezestat can be adjusted to the
appropriate setting.
Note: Our warranty does not cover the evaporator from
freezeups. It is vital that the freezestat is set properly.

6. Turn on the control power by pressing the Power button. The

digital displays should now be illuminated.
7. Due to extreme temperatures during shipment, some of the safeties may have tripped. If this is the case, manually reset the
Freezestat if necessary and then press the Reset button on the
front panel.
8. Once all alarm conditions have been cleared, press the Start
button. At this time, the pump should start running. If the controller is calling for cooling, the compressor may also start at this
time.
Page 13

9.

Check the rotation of the pump. If the pump is running backwards, switch two of the main power leads, after shutting off the
disconnect switch. The pressure gauge on the back of the unit
should be reading at least 20 PSI.

10. The coolant flow out to process can be adjusted by using the cock
valve on the supply line just inside the chiller cabinet. If the
process does not create much of a pressure drop, the cock valve
may have to be throttled in order to maintain the flow through the
chiller at an acceptable level. If the flow is more than double the
nominal flow rating, the cooling capacity of the chiller may be
reduced.
11. Temperature adjustment is the next step in putting the chiller in
operation. Adjust the controller set point to the desired temperature. The chiller should now be controlling to that temperature.
Please note that if there is no load on the chiller, the compressor
will cycle on and off causing swings in temperature of up to 10F
(5C).
12. Once proper flow and temperature are achieved, press the Stop
button and allow the water level in the tank to stabilize. Fill the
tank, replace the screw cap, and replace the top panel on the
cabinet.
The unit is now ready to be placed into service.

Page 14

CONTROL PANEL OPERATION

Control Panel

The chiller includes a microprocessor controller designed to perform

all control functions directly from the front panel. When a button is
depressed, a click will be felt and the corresponding LED will be
energized. Only one button should be pressed at a time.
The Microprocessor Control Fault Logic Table shown below provides
the basic control fault logic for the microprocessor controller. The
following section details each of these diagnostics and the control
buttons.

Microprocessor Control Fault Logic

Fault
No Flow
High Refrigerant Pressure
Low Refrigerant Pressure
Freezestat
Low Oil Pressure
Over Set Point
Under Set Point
Low Water Level
High Water Temperature
Probe Fault
Low Power
Pump Overload
Compressor Overload
High Temperature Safety

Alarm
Manual
Remote
Alarm
Compressor Pump
Reset
Reset
Alarm
Indication Shutdown Shut Off Required Required Activated
LED
Yes
Yes
No
No
Yes
LED
Yes
Yes
Yes
No
Yes
LED
Yes
No
Yes
No
Yes
LED
Yes
No
Yes
Yes
Yes
LED
Yes
Yes
Yes
Yes
Yes
LED
No
No
No
No
Yes
LED
Yes
No
Yes
No
Yes
LED
No
No
No
No
No
LED
No
No
No
No
No
LED
Yes
Yes
Yes
No
Yes
Pr OFF
Yes
Yes
Yes
No
Yes
Err 126
Yes
Yes
Yes
Yes
Yes
Err 127
Yes
Yes
Yes
No
Yes
Err 128
Yes
Yes
Yes
No
Yes

Alarm Reset button or Stop button on control board must be pressed.

Safety control must be manually reset before the controller can be reset.
Activates the alarm horn (if included) and closes the alarms contacts (if included).

Page 15

Control Buttons
This unit was either shipped to display temperatures in F or C. Do
the following to change the display.
1. With the power connected and the control power off, hold the Stop
button. While holding the Stop button press the Power button.
When the controller illuminates, release both buttons.
2. The To Process display will read "Unt". The Set Point display will
show either "F" or "C" depending on the current display units
selected. If the current selected units are "F" press the down key.
If the current selected units are "C" press the up key.
3. The Set Point display should now indicate the desired display
units. Press the Start button to store the new selection into the
controller memory.
4. Press the Power button once to exit this function then press the
Power button again to restore controller power.

! Power
Depressing the Power button will switch the control power on or off.
Control power must be initiated before the chiller can be started by
the Start button or by remote on/off contacts.

! Start
Depressing the Start button will start the pump and enable the compressor. The compressor will start only if the microprocessor is calling
for cooling because the actual To Process temperature is higher than
the Set Point temperature.

Note: Once the compressor has cycled off, it will not restart for
two minutes because of an internal anti-cycle time delay.

! Stop
Depressing the Stop button will shut off the compressor and pump,
and clear all fault signals.

Page 16

! Alarm Reset
Depressing the Alarm Reset button will reset any fault indicator that
has been activated on the control board. This includes any LED
indicators or alarm codes. The Freezestat, Low Oil Pressure, and
Pump Overload require a mechanical safety to be manually reset
before the control board can be reset.
Note: If the condition still exists that originally caused the
alarm indication, the alarm may be reactivated as soon as it is
reset.

! Alarm Silence
The Alarm Silence button is not functional unless the Alarm Horn
option or the Remote Alarm contacts option has been purchased. If
the Alarm Horn option has been purchased, depressing the Alarm
Silence button will disable the horn. The horn will not reactivate until
the alarm has been reset and a subsequent alarm has been triggered.
If the Remote Alarm contacts option has been purchased, depressing
the Alarm Silence button will reopen the contacts which were closed
when the alarm occurred. The contacts will not close again until the
alarm has been reset and a subsequent alarm has been triggered.

! Lower Set Point Temperature

Each time that the ! button is depressed momentarily, the Set Point
temperature will be decreased by 1F (or 1C). If the ! is held down,
the Set Point temperature will continue to decrease until the button is
released.

! Raise Set Point Temperature

Each time that the # button is depressed momentarily, the Set Point
temperature will be increased by 1F (or 1C). If the # is held down,
the Set Point temperature will continue to increase until the button is
released.

Page 17

Diagnostic LEDs
! No Flow
The No Flow LED will be illuminated if the flow through the chiller is
below the preset acceptable level. When the Start button is depressed,
this safety is defeated for a period of 20 seconds in order for the pump
to establish flow. The No Flow LED may remain illuminated during
this 20 second period. This safety will shut off the pump and the
compressor. If the chiller has been shut down by the No Flow safety,
the Start button must be depressed in order to restart the pump and
reset the 20 second time delay.

! High Refrigerant Pressure

If the compressor discharge refrigerant pressure exceeds the setting
on the high refrigerant pressure safety, the compressor and pump will
shut off and the High Refrigerant Pressure LED will be illuminated.
The High Refrigerant Pressure fault can be reset by pressing the
Alarm Reset button, as long as the refrigerant pressure has dropped
back down below the safetys cutout level.

! Low Refrigerant Pressure

If the compressor suction pressure drops below the setting on the low
refrigerant pressure safety, the compressor will shut off, the pump will
remain running, and the Low Refrigerant Pressure LED will be illuminated. The Low Refrigerant Pressure fault can be reset by pressing
the Alarm Reset button, as long as the refrigerant pressure has risen
back up above the safetys cutout level.

! Freezestat
If the coolant temperature being delivered to the process drops below
the setting on the Freezestat, the compressor will shut off, the pump
will remain running, and the Freezestat LED will be illuminated. The
Freezestat should be set 10F (5C) above the freezing point of the
glycol solution and 10F (5C) below the minimum operating temperature. The Freezestat is factory set at 40F (4C). In order to reset the
Freezestat fault, press the Alarm Reset button after resetting the
mechanical thermostat (labeled Freezestat) inside the electrical
enclosure.
Page 18

! Low Oil Pressure

Only chillers with a semi-hermetic compressor are equipped with a
Low Oil Pressure safety switch. On these units, if the oil pressure in
the compressor crankcase drops below the factory-set level on the oil
pressure switch, the compressor and pump will shut off, and the Low
Oil Pressure LED will be illuminated. In order to reset the Low Oil
Pressure fault, press the Alarm Reset button after resetting the mechanical pressure switch located inside of the cabinet near the
compressor.

! Over Set Point

The Over Set Point LED will be illuminated if the To Process temperature exceeds the Set Point temperature by more than 5F (or 3C).
This fault causes only an alarm indication (horn and/or remote contacts), and the chiller will continue to operate. Although the Over Set
Point LED will turn on immediately whenever the temperature is out
of range, the alarm relay is disabled for 30 minutes after start-up or
after a change in set point. The alarm will automatically clear when
the temperature comes back into range.

! Under Set Point

The Under Set Point LED will be illuminated if the To Process temperature drops below the Set Point temperature by more than 10F (or
5C). This fault will shut off the compressor, but the pump will continue to run. Although the Under Set Point LED will turn on immediately whenever the temperature is out range, the alarm relay is
disabled for 30 minutes after start-up or after a change in set point.
This fault can be reset by pressing the Alarm Reset button.

! Pump On
The Pump On LED will be illuminated whenever the pump is running. If the pump is shut off due to a safety, the Pump On LED will
turn off. The Start button must be pressed in order to restart the
pump.

Page 19

! Compressor On
The Compressor On LED will be illuminated whenever the compressor is running. The Compressor On LED will cycle on and off with the
compressor. The compressor will not come on unless the pump is
already running and the To Process temperature is above the Set
Point temperature.

Note: During normal operation, the compressor may cycle on

and off. An internal anti-cycle time delay will not allow the
compressor to restart for two minutes after it has cycled off.

! Partial Load
The Partial Load LED will be illuminated whenever the microprocessor energizes the hot gas bypass solenoid valve. This valve is cycled in
order for the chiller to maintain a constant To Process temperature
even when there is only a partial load. The longer that this LED stays
on, the more unused excess capacity is available from the chiller. If
the Partial Load LED stays off, the chiller is fully loaded by the heat
from the process. If the Partial Load LED stays on, the chiller has a
very small load on it from the process. If this low load condition
persists, the To Process temperature may begin to drop below the Set
Point temperature, and when it reaches 7F (or 4C) below the Set
Point temperature, the compressor will cycle off. The compressor will
come back on when the To Process temperature rises back up to the
Set Point temperature and the anti-cycle two minute time delay relay
has timed out.

! Water Make-Up
The Water Make-Up LED is only functional if the Water Make-Up
option is purchased with the chiller. When the water level in the
reservoir drops below the lower limit of the float switch, the water
make-up solenoid valve is opened and the Water Make-Up LED is
illuminated. When the water level rises to the upper limit of the float
switch, the water make-up solenoid is closed and the Water Make-Up
LED turns off. The microprocessor will also close the water make-up
solenoid valve if it has been open for a period of ten minutes. This is
done to help prevent further problems if a water leak has developed in
the system. If this occurs, the Water Make-Up LED will turn off, but
the Low Water Level LED will remain illuminated.

Page 20

! Low Water Level

The Low Water Level LED is only functional if either the Low Water
Level option or the Water Make-Up option is purchased. When the
water level in the reservoir drops below the lower limit of the float
switch, the Low Water Level LED is illuminated. When the water
level rises to the upper limit of the float switch, the Low Water Level
LED will shut off.

! High Water Temperature

The High Water Temperature LED will be illuminated if the To Process temperature rises more than 10F (or 5C) above the Set Point
temperature. The High Water Temperature LED will turn off when
the water temperature drops back within 10F (or 5C). This fault
will not stop operation of the chiller.

! Probe Fault
The Probe Fault LED will illuminate if the signal from the thermocouple is out of tolerance. This fault will also shut off the compressor
and the pump. It can be reset by pressing the Alarm Reset button.

Diagnostic Error Codes

Several different error codes may be displayed on the digital readouts
labeled To Process and Set Point. Most of the possible error codes
indicate some type of failure in the microprocessor controller. There
are also four specific faults listed below which show up as error codes.
If there is an error code other than these four, try to reset the chiller
by shutting the power off and then turning it back on. If this does not
work, make a note of the error code and contact the Customer Service
Department for further assistance.

! Pr Off
If the chiller is running and main power is discontinued or drops more
than 10% below the normal operating voltage, the unit will shut down
and the Pr OFF fault will be indicated on the digital displays. This
fault condition can be cleared by pressing the Stop button.

Page 21

! Err 126
The Err 126 fault code will be indicated on the digital displays if the
pump has gone off due to the pump overload. In order to reset this
fault, press the Alarm Reset button after resetting the pump overload
inside the electrical enclosure.

! Err 127
Some units equipped with a semi-hermetic compressor include this
function. The Err 127 fault code will be indicated on the digital displays if the compressor has gone off due to the internal compressor
thermal overload. This fault will also shut off the pump. The thermal
overload will automatically reset when the compressor motor winding
temperature drops back into the normal operating range. Once this
occurs, the fault can be reset by pressing the Alarm Reset button.

Note: Units equipped with a scroll compressor will require

manual reset of the compressor motor overload module.

! Err 128
The Err 128 fault code will be indicated on the digital displays if the
chiller has been shut off due to the high temperature safety. This
safety will shut off both the pump and compressor. This safety is
triggered if the To Process temperature rises more than 10F (or 5C)
above the maximum operating temperature for that particular chiller.
The maximum operating temperature for each chiller is noted on the
nameplate. The To Process temperature must be over the limit for
three minutes before this safety will be triggered, and the fault is
defeated for a period of 30 minutes from the time the Start button is
pressed or the Set Point temperature is changed. This fault can be
reset by pressing the Alarm Reset button.

Control Options
! Return Water Temperature Display
If the Return Water temperature display option is purchased, the To
Process digital display can be used to view To Process temperature or
Return Water temperature. To view the Return Water temperature,
hold down the ! and # buttons simultaneously. Once the buttons are
released, the display will return to To Process temperature.
Page 22

! Low Coolant Level Indicating Light

If the Low Coolant Level indicating light option has been included,
this light on the control panel will be illuminated if the coolant level
in the reservoir drops below the preset level. The light will turn back
off once the coolant level has been restored to the proper operating
level. This light is simply an indication that coolant should be added
to the reservoir in the near future. The chiller will continue to operate
normally when this light is on.

! Remote On/Off Contacts

If the Remote On/Off contacts are included, the chiller can be turned
on and off via a remote contact closure. Two contacts are provided on
the terminal block in the control panel. These contacts are to be wired
to a remote contact closure device. Switching the contacts from open
to closed simulates pressing the Start button on the control panel.
Switching the contacts from closed to open simulates pressing the
Stop button. Please note that the Remote On/Off contacts are not
functional until the controls have been energized by pressing the
Power button. This option also includes a remote/local toggle switch
which allows the operator to disable the remote contacts for safety
purposes while the unit is being serviced.
Note: Do not introduce any external voltage to these contacts,
as this will result in damage to the microprocessor, which will
not be covered by the warranty.

! Remote Alarm Contacts

If the Remote Alarm contacts are included, a set of contacts will be
closed when there is an alarm condition. Refer to the Microprocessor
Control Fault Logic table to determine which faults will trigger the
Remote Alarm contacts. The contacts can be reopened by clearing the
fault or by pressing the Alarm Silence button.

! Alarm Horn
If the Alarm Horn option is purchased, the control panel will be fitted
with an alarm horn which will be activated by certain faults. Reference the Microprocessor Control Fault Logic table to determine which
faults will trigger the horn. The horn can be silenced by clearing the

Page 23

fault or by pressing the Alarm Silence button. If this option is selected in conjunction with the remote control panel, the horn will be
mounted on the chiller and not the panel.

! Remote Control Panel

With the Remote Control Panel option, the display board is mounted
in a separate NEMA-1 enclosure. The controller and the chiller are
connected by a factory wired cable 50 feet long. All control functions
are available to the operator at the location of the remote panel and
no control functions are available at the location of the chiller.

! SPI Communications
If the SPI Communications option is included, an RS-485 communication port will be located below the control panel on the front of the
chiller. The serial communications will be multi-drop, half duplex, SPI
3.01 compatible. This option allows the chiller to communicate with
another piece of equipment that also has SPI protocol capabilities.
The following SPI communications are supported by the
microprocessor.
$
$
$
$
$

Process Temperature Setpoint

High Deviation
Low Deviation
Process Status
To Process Temperature

The microprocessor is designed to accept inputs and deliver outputs

according to SPI protocol. There must also be a computer or another
piece of equipment which is equipped with the SPI protocol in order
for the communications from the chiller to be of any use. The programming of this computer and/or other equipment is not the responsibility of the manufacturer.

Note: The manufacturer is not responsible for SPI protocol

programming beyond what is included in the microprocessor
controller.
When the SPI option is included, there is a second set of DIP switches
included on the back of the main control panel. This set of DIP
switches is labeled COMM. All DIP switch adjustments that follow
are to be made on the COMM set. Do not adjust any DIP switches on
the CONFIG set.

Page 24

Note: All DIP switch changes must be made with power

disconnected.

In order to activate the SPI protocol, DIP switch #8 must be set to the
On position. To deactivate the SPI communication, set DIP switch
#8 to the Off position.
If more than one piece of equipment is going to be on the same communications network, the base address will have to be changed so that
each unit has a unique address. This is done by changing one or more
of the DIP switches to the Off position. The base address is 32
decimal. Changing these switches causes the following address
change.
DIP Switch 1 OFF
DIP Switch 2 OFF
DIP Switch 3 OFF
DIP Switch 4 OFF
DIP Switch 5 OFF

Add one to base address

Add two to base address
Add four to base address
Add eight to base address
Add sixteen to base address

The BAUD rate can be adjusted to the appropriate setting by using the
following chart.
BAUD Rate
1,200
2,400
4,800
9,600

DIP Switch #6
ON
OFF
ON
OFF

DIP Switch #7
ON
ON
OFF
OFF

Page 25

CHILLER OPERATION
The following diagram illustrates the basic operation of a water cooled
portable chiller. There is a brief description of the coolant circuit and
the refrigerant circuit. Keep in mind that this drawing is general in
nature and that some of the components and piping may change
depending on which options have been selected.

Typical Piping Schematic

Page 26

Coolant Circuit
The pump draws coolant from the reservoir and circulates it through
the evaporator. It is in the evaporator where the heat is transferred
from the coolant to the refrigerant. The temperature of the coolant
being delivered to the process is controlled by adjusting the amount of
heat transferred in the evaporator.
After leaving the evaporator, the coolant passes through a manifold
which includes a freezestat sensing bulb, flow switch (or pressure
switch), thermocouple and process supply throttling valve. The
freezestat sensing bulb, flow switch and pressure switch are safety
controls that are connected to the microprocessor. The thermocouple
senses the temperature of the coolant being delivered to process and
communicates this temperature to the microprocessor. The process
supply throttling valve can be used to adjust the flow out to process.
Opening this valve will increase the flow to process while closing it
will result in a reduction of flow.
This manifold is connected directly to the process water supply connection on the back of the chiller. Once the coolant passes through
this manifold, it is delivered out to process where it picks up the
process heat before returning to the process water return connection.
From this connection, the coolant returns directly to the reservoir
where the whole sequence starts over.
A small coolant bypass line tees off of the manifold between the thermocouple and the supply throttling valve. This line allows the chiller
to operate with sufficient flow through the evaporator even if the flow
is restricted or completely shut off through the process. On air cooled
models AQ0A0H through AQ0A03 and water cooled models AQ0W02
through AQ0W05 chillers, the bypass is a small copper line running
from the process supply manifold to the process return line. On air
cooled models AQ0A06 through AQ0A10 and water cooled models
AQ0W08 through AQ1W40, the bypass is a hose that runs from the
process supply manifold directly back into the reservoir. There is a
cock valve located in this line right where it connects to the reservoir.
This valve can be adjusted depending on how much flow is required by
the process.
Note: Closing this valve off too far may result in a situation
that could damage components in the chiller. The main purpose of the bypass line is to avoid deadheading of the pump and
reduce the possibility of a freeze-up.

!
Page 27

Refrigerant Circuit
The heat that is transferred in the evaporator from the coolant to the
refrigerant is used to change the state of the refrigerant from a liquid
to a gas. After leaving the evaporator, the refrigerant passes through
the suction accumulator. The purpose of the suction accumulator is to
trap any liquid refrigerant that may exit the evaporator during startup. The refrigerant gas passes through to the compressor. The
trapped liquid in the suction accumulator will eventually boil off and
move on to the compressor.
The compressor is the heart of the refrigeration circuit. It takes the
cool, low pressure gas entering the compressor and compresses it
which creates the hot, high pressure gas that exits the compressor.
Since the compressor is not 100% efficient, some extra heat is added to
the refrigerant as it is being compressed.
The hot, high pressure gas that exits the compressor is delivered to
the condenser. In the condenser, the heat is transferred from the
refrigerant into the air stream or water stream that is passing
through in the opposite direction. As the heat is transferred, the
refrigerant changes from a gas to a liquid. The condenser has been
sized to remove the heat from the process load and the heat that was
added by the compressor.
After leaving the condenser, the liquid refrigerant passes through the
receiver (air cooled units only), the filter drier and sight glass. The
filter drier filters out any particles and/or moisture from the refrigerant. The sight glass is used to monitor the stream of liquid refrigerant. The liquid refrigerant then passes through the thermal expansion valve (TXV) which meters the flow into the evaporator where the
process starts all over again.
Capacity and temperature control is accomplished with a hot gas
bypass system on these chillers. If the chiller is catering to a partial
load from the process, the coolant supply temperature would normally
tend to drop. The microprocessor senses this drop in temperature, and
opens the hot gas bypass solenoid valve. When this valve is open,
some of the hot compressor discharge gas is directed to the inlet of the
evaporator instead of going through the condenser. This puts an
additional heat load on the evaporator which brings the coolant temperature back up to set point. With PID control from the microprocessor and the solenoid cycling as much as once every ten seconds, coolant temperature is usually controlled within 1F (0.5C) of set point
even with loads as low as 10% - 25% of full capacity.
Page 28

If the process heat load is extremely low, or even nonexistent, the hot
gas bypass system may not be able to put enough of a false load on the
evaporator, and the coolant temperature will begin to drop. When the
coolant temperature drops to 7F (4C) below the set point temperature, the controller will shut the compressor off. When the coolant
temperature rises back to the set point temperature, the compressor
comes back on.
The compressor will remain off for at least two minutes to prevent
short cycling.

Page 29

CHILLER CONSTRUCTION
Refrigeration Components
! Compressor
Hermetic
If the model number of the chiller begins with AQ0, then the chiller is
equipped with a hermetically sealed compressor. Both the compressor
and the motor are encased together in the enclosure. Inside the
casing, the compressor is spring mounted which extends compressor
life and provides quiet operation. The motor windings are cooled by
the cool refrigerant suction gas, and there is an internal thermal
overload to protect the windings from overheating. The compressor
also includes a crankcase heater which will boil off any liquid refrigerant that may have migrated into the compressor crankcase while the
chiller was shut off. The compressor is lubricated with oil that travels
throughout the system with the refrigerant.
Semi-Hermetic
If the model number of the chiller begins with AQ1, then the chiller is
equipped with a semi-hermetic compressor. A semi-hermetic compressor has all of the features of the hermetic compressor except that the
semi-hermetic compressor has removable heads so that it can be
taken apart to be serviced or rebuilt. The semi-hermetic compressor is
not internally spring mounted like the hermetic compressor, so it
tends to run a little louder.
Scroll
If the model number of the chiller begins with AQ2, then the chiller is
equipped with a scroll compressor(s). Both the compressor and the
motor are encased together and solidly mounted in the enclosure. The
compressor is unidirectional and will only pump refrigerant when
properly phased. The motor windings are cooled by the cool refrigerant suctions gas, and there is an internal thermal overload to protect
the windings from overheating. The compressor is lubricated with oil
that travels throughout the system with the refrigerant.

! Air Cooled Condenser (Air Cooled Units Only)

The air cooled condenser is constructed of heavy gauge copper tubing
and aluminum fins for maximum heat transfer capabilities. The
condensers have been generously sized so that chillers can operate
with full cooling capacities with ambient air temperatures of up to
95F (35C). With higher ambient temperatures, the chiller will lose
Page 30

approximately 1% of its cooling capacity per 1F (0.5C) above 95F

(35C). The chiller should be able to operate with ambient temperatures of up to 110F (43C).
The fan(s) draw the air flow through the condenser and blows the
warm discharge air through the chiller cabinet and out the other side.
The fan(s) are designed to draw sufficient air flow through the chiller
as long as there are no obstructions. The fan(s) are not capable of
drawing air in through ductwork on the intake or discharging air
through ductwork on the exhaust. The discharge air will be approximately 35F (20C) warmer than the intake air.

! Water Cooled Condenser (Water Cooled Units Only)

There are two different types of water-cooled condensers used in these
chillers. Models AQ0W02 through AQ0W05 use a tube-in-tube style
condenser, while models AQ0W08 through AQ1W40 rely on a shelland-tube type condenser.
The tube-in-tube condensers have a steel outer tube with a copper
inner tube. The refrigerant passes between the steel and the copper,
while the condenser water flows through the copper tube in the opposite direction from the refrigerant.
The shell-and-tube condensers are constructed with a steel shell,
removable cast iron end bells, and a bundle of copper tubes. The
condenser water passes through the copper tubes, while the refrigerant passes in the opposite direction around the tubes.

! Condenser Water Regulating Valve (Water Cooled Units Only)

A condenser water regulating valve is provided as standard on models
AQ0W02 through AQ1W15 chillers. On models AQ1W20 through
AQ1W40 it is available as an option. This valve is located in the
condenser water piping at the inlet of the condenser. It regulates the
flow of water through the condenser in order to maintain the high-side
refrigerant pressure. This valve is set at the factory and should only
be adjusted by a qualified refrigeration technician. This valve only
passes as much water as is required to maintain the refrigerant
pressure, so less water will be required if the water temperature is
lower than the design 85F (29C).

Page 31

Note: The condenser water regulating valve may not completely

shut-off water flow when the chiller is not operating. If flow
must be completely stopped for any reason, a shut-off valve
must be used. Make sure the shut-off valve is reopened before
restarting the chiller.

! Evaporator
There are three different types of evaporators used in these chillers.
Air cooled models AQ0A0H through AQ0A03 and water cooled models
AQ0W02 and AQ0W03 use a tube-in-tube style evaporator. Air cooled
models AQ0A06 through AQ0A10 and water cooled models AQ0W05
through AQ1W30 use a brazed plate style evaporator. Water cooled
models AQ1W35 and AQ1W40 use a shell-and-tube evaporator.
The tube-in-tube evaporators have a steel outer tube with a copper
inner tube. The refrigerant passes between the steel and the copper,
while the coolant flows through the copper tube in the opposite direction from the refrigerant.
The brazed plate evaporators are constructed with stainless steel
plates and copper brazing. The refrigerant passes between every
other set of plates, while the coolant flows on the other side of the
plates in the opposite direction.
The shell-and-tube evaporators are constructed with a steel shell
around a bundle of copper tubes. The refrigerant passes through the
copper tubes, while the coolant passes in the opposite direction around
the tubes.

! Thermostatic Expansion Valve (TXV)

The TXV separates the refrigerant high pressure/temperature on the
condenser side from the refrigerant low pressure/temperature on the
evaporator side. The TXV meters the amount of refrigerant into the
evaporator in the precise quantity to match the process load. This
valve uses a pressure limiting design and has been factory set for
proper operation. Only a trained refrigeration service technician
should adjust this valve.
The difference between the saturated evaporative temperature and
the suction line temperature at the TXV sensor bulb location is called
superheat. The superheat is factory set for 10F to 12F (5C to 6C)
and should never exceed 15F (8C).
Page 32

! Refrigerant Sight Glass

The refrigerant sight glass is located in the liquid line immediately
ahead of the expansion valve. It allows the operator or service technician to observe the flow of liquid refrigerant. Prolonged periods of
foaming in the sight glass may indicate a low refrigerant condition or
a restriction in the liquid line.
Note: Occasional bubbling in the sight glass may occur at a
time when load conditions are changing and the thermostatic
expansion valve is adjusting to the new conditions. This momentary occurrence is a result of normal chiller operation.

The sight glass can also be used to check if there is moisture in the
refrigeration system. If there is moisture in the system, the green dot
in the center of the sight glass will turn yellow. If this occurs, the
chiller should be serviced immediately.

! Refrigerant Filter Drier

The filter drier is located in the liquid line between the condenser (or
receiver if the chiller is air cooled) and the refrigerant sight glass. It
is designed to remove any moisture and/or foreign matter that may
have gotten into the refrigerant stream. Moisture and foreign matter
can cause serious damage to the components of a refrigeration system.
For this reason, it is important that the chiller be equipped with a
clean filter drier. Replace the filter drier any time the following
conditions occur.
1. The refrigeration system is opened to the atmosphere for repairs
or maintenance.
2. Moisture is indicated in the sight glass (the green dot has changed
to yellow).
3. An excessive pressure drop develops across the filter drier. This is
indicated by a significant temperature difference between the
filter inlet and outlet.

! Liquid Receiver (Air Cooled Units Only)

The receiver is a refrigerant vessel which holds excess liquid refrigerant that may not be required in the system under certain operating
Page 33

conditions. It is located in the liquid line directly after the condenser.

The receiver is supplied with a shut-off valve on the outlet which
enable pump-down of the refrigeration circuit for servicing.

! Suction Accumulator
The suction accumulator is the refrigerant vessel located in the suction line between the evaporator and the compressor. The purpose of
the suction accumulator is to trap any liquid refrigerant before it can
enter the compressor. The refrigerant gas is allowed to pass through,
while the liquid will remain in the bottom of the vessel. The trapped
liquid will eventually boil off and move on to the compressor.

! Hot Gas Bypass Valve

This valve is located in the refrigerant line that runs from the compressor discharge to the evaporator inlet. It is designed to provide the
compressor with a continuous full load even when the chiller is catering to a partial load from the process. This is accomplished by directing some of the hot compressor discharge gas directly back into the
evaporator instead of going through the condenser. The amount of hot
gas that is used is controlled by the microprocessor controller. Eliminating cycling of the compressor is extremely desirable as it significantly extends its lifetime expectancy.

Wet-Side Components
! Reservoir
On chillers up to 30 HP, the coolant reservoir is mounted on top of the
shelf in the chiller and is easily accessible by removing the top panel.
The reservoir is made of polyethylene and is fully insulated. A slot
has been made in the insulation so that the coolant level can be observed without removing any panels. There is a six inch screw cap on
the top of the reservoir that can be used for filling and cleaning. There
is a small hole in this cap so that air can vent to the atmosphere.

!
Page 34

Note: These reservoirs are not designed to be pressurized.

Modifications to the chiller that would result in pressurization
of the reservoir will void the warranty.

Air cooled models AQ0A0H through AQ0A03 and water cooled models
AQ0W02 through AQ0W05 are equipped with an eight gallon reservoir, air cooled models AQ0A06 through AQ0A10 have a 20 gallon
reservoir, while water cooled models AQ0W08 through AQ1W30 have
a 45 gallon reservoir. During chiller operation, these reservoirs should
be at least half full. For most installations, these tanks have sufficient
capacity to handle the coolant that drains back from the piping when
the chiller is shut off. For overhead piping runs of more than 50 feet,
special precautions will have to be made during installation. See
details on Overhead Piping diagram for overhead piping installations.
Water cooled models AQ1W35 and AQ1W40 are equipped with a 40
gallon cylindrical galvanized steel reservoir mounted inside the
cabinetry above the pump. This reservoir is filled using the fill-port
that extends through the top of the cabinet. There is a sight glass
located at one end of the tank. These tanks cannot be pressurized,
and it is very likely that overhead piping will require the special
precautions illustrated on the Overhead Piping Diagram.

! Coolant Pump
The close-coupled centrifugal pump is equipped with a mechanical
seal. The 1 HP pumps are constructed of bronze, while all other
sizes are bronze-fitted cast iron construction. Each pump is factory
tested for the specified operating conditions. The ODP motor meets
NEMA specifications and industry standards.

! Pressure Gauge
A pressure gauge is mounted on the back panel of the chiller. This
gauge displays the pressure of the coolant at the discharge of the
pump. It can be used to determine the approximate point on the
pump curve in which the pump is operating.

! Process Supply Throttling Valve

This cock valve is located just inside the cabinet on the process supply
line. It can be accessed by removing the top panel of the chiller. The
purpose of this valve is to enable the operator to reduce the coolant
flow out to process. It is possible with certain applications that this
valve will need to be closed slightly in order to keep the flow through
the evaporator within the design parameters. For most applications,
this valve should be wide open.

Page 35

Note: Although partially closing this valve will raise the pressure reading on the pressure gauge, the pressure being delivered to the process will actually be reduced. Throttling this
valve will always reduce the flow out to process.

Operating and Safety Controls

!

Fan Cycling Controls (Air Cooled Units Only)

The fan cycling controls are designed to turn the condenser fans on
and off in order to maintain a constant compressor discharge refrigerant pressure. During normal operation, the fans will cycle on and off
based upon the process heat load and ambient air conditions.

Note: It is possible that a condenser fan will continue to operate after the chiller has been shut-off. This fan will automatically shut off as soon as the refrigerant pressure drops below
the preset level on the fan cycling control.

! High Refrigerant Pressure Switch

The high refrigerant pressure switch is designed to limit the compressor discharge pressure so that it stays within the design parameters of
the compressor. The switch is located inside the small electrical
enclosure next to the compressor. The switch can be reset by pressing
the Alarm Reset button on the control panel. The setting on this
switch is not adjustable on most models. If it is adjustable, no changes
should be made without prior approval from the factory.

! Low Refrigerant Pressure Switch

The low refrigerant pressure switch is designed to limit the compressor suction pressure so that it stays within the design parameters of
the compressor. The switch is located in the small electrical enclosure
next to the compressor. The switch can be reset by pressing the Alarm
Reset button on the control panel. The setting on this switch is adjustable; however, no changes should be made to the setting without
prior approval from the factory.

Page 36

! Freezestat
The freezestat control is a mechanical thermostat which senses the
coolant temperature separately from the microprocessor controller.
This safety is designed to limit the temperature of the coolant leaving
the evaporator and prevent any possible freeze-up situations. This
control should be set 10F (5C) below the minimum coolant supply
temperature, and there should be a sufficient glycol concentration for
10F (5C) below the freezestat setting. Manual reset is required.
Note: It is critical that the freezestat is set properly and that
there is sufficient glycol in the system to correspond with the
freezestat setting. Freeze-ups can cause extensive damage to
several components in the chiller, and the warranty does not
cover repairs required due to a freeze-up.

! Coolant Pressure Switch

Air cooled models AQ0A0H through AQ0A03 and water cooled models
AQ0W02 through AQ0W05 are equipped with a coolant pressure
switch. This switch is located in the process supply piping manifold.
It is designed to shut the unit down if there is insufficient coolant
pressure. This switch is adjustable; however, the setting should not be
changed without prior authorization from the factory. If the chiller
shuts down due to low coolant pressure, it can be restarted by pressing the Start button on the control panel. This switch is disabled for
twenty seconds after the Start button is pressed so that the pump can
develop pressure and make the switch.

! Coolant Flow Switch

Air cooled models AQ0A06 through AQ0A10 and water cooled models
AQ0W08 through AQ1W40 are equipped with a coolant flow switch.
This switch is located in the piping directly before the evaporator
inlet. It is designed to shut the unit down if there is insufficient
coolant flow through the evaporator. The switch is adjustable; however, no adjustments should be made without prior approval from the
factory. If the chiller shuts down due to low coolant flow, it can be
restarted by pressing the Start button on the control panel. This
switch is disabled for 20 seconds after the Start button is pressed so
that the pump can develop flow and make the switch.

Page 37

STANDARD OPTIONS
There are many different combinations of options available on portable chillers. Many special options are provided so that the chiller
can meet the special requirements of a particular process. It is not
practical to include all of the special options in this manual; therefore,
in instances where these options have been included, it may be necessary to refer to separate documentation for the specifics of the special
features. The following are the most common standard options.

! Automatic Water Make-Up

With this option, a water supply can be connected to the chiller so that
the water level in the reservoir is automatically maintained. When
the water level in the reservoir drops below the low-level on the float
switch, a solenoid valve will be opened to allow fresh water into the
system. When the water level reaches the high-level on the float
switch, the solenoid valve is closed.

Note: This option is not normally recommended for systems

that depend on a glycol solution to prevent freeze-ups. Automatic water make-up may cause reduction of the glycol concentration, which may result in a freeze-up.

! Automatic Water Bypass Valve

With this option, the valve in the bypass line is upgraded to an automatic pressure regulating valve. This valve will automatically adjust
the flow through the bypass line in order to maintain a maximum
water pressure to process. This constant pressure will be maintained
even with changing flow conditions from the process. The pressure
setting on this valve can be changed by adjusting the tension of the
spring within the valve. To raise the pressure, turn the stem of the
valve in the clockwise direction, and turn the stem counterclockwise to
lower the pressure.

Page 38

Note: Caution should be taken when setting this valve on units

that are equipped with a pressure switch instead of a flow
switch (1/2 HP through 5 HP units). Setting the pressure too
high may result in deadheading of the pump and freezing up of
the evaporator. Each unit leaves the factory with the valve set
properly.

! Crankcase Pressure Regulating Valve

On a standard portable chiller the To Process temperature can be set
anywhere in the range from 30F (-1C) to 60F (16C). With this
option included, the To Process temperature can be set up to 75F
(24C). The microprocessor controller will limit the upper To Process
set point to either 60F (16C) or 75F (24C) depending on whether or
not this option is included.
The purpose of this valve is to limit the refrigerant suction pressure
going to the compressor. Higher To Process coolant temperature will
result in a higher suction gas pressure. Higher suction pressure
causes the compressor to do more work which will eventually cause
the motor to fail. The CPR valve brings the suction gas temperature
back to an acceptable level for the compressor.

! Nonferrous Construction
Standard chillers have several components in contact with the coolant
that are made of mild steel. This is acceptable for most applications;
however, for applications that require extremely clean water, distilled
water, or deionized water, the nonferrous construction option is
strongly recommended. With this option, all components in contact
with the process fluid are constructed of nonferrous materials. These
materials include stainless steel, bronze, brass, copper, plastic and
rubber.

! Upgraded Pumps
The standard pumps that have been selected for each size chiller will
meet the requirements of most applications; however, in certain instances, larger pumps may be required to provide the desired flow and
pressure for a specific application. The horsepower of the pump will
be indicated on the nameplate on the chiller.

Page 39

PREVENTIVE MAINTENANCE
Once your portable chiller has been placed into service, the following
maintenance procedures should be adhered to as closely as possible.
The importance of a properly established preventive maintenance
program cannot be overemphasized. Taking the time to follow these
simple procedures will result in substantially reduced downtime,
reduced repair costs, and an extended useful lifetime for the chiller.
Any monetary costs of implementing these procedures will almost
always more than pay for itself.
To make this as simple as possible, a checklist should be prepared
which lists the recommended service operations and the times at
which they are to be performed. On the following page, we have
included a checklist that can be used for this purpose. Notice that
there are locations for voltage readings, amperages, etc. so that they
can be monitored over time. With this information, maintenance
personnel may be able to correct a potential problem before it causes
any downtime. For best results, these readings should be taken with a
full heat load from process, preferably with similar operating conditions each time.
The following is a list of suggested periodic maintenance.

! Once a Week
1. (Air Cooled Units Only) Check the surface of the air cooled
condenser coil for dirt and debris. Clean out with compressed air
if necessary.
2. Check to make sure that the To Process temperature is maintained
reasonably close to the Set Point temperature. If the temperature
stays more than 5F (3C) away from the set point, there may be a
problem with the chiller. If this is the case, refer to the Troubleshooting Chart or contact the Service Department.
3. Check the pump discharge pressure on the gauge on the back
panel of the chiller. Investigate further if the pressure starts to
stray away from the normal operating pressure.
4. Check the coolant level in the reservoir. Replenish if necessary
making sure to take proper precautions to maintain the appropriate glycol concentration.
5. Check coolant circulation pump for leaks in the seal area. Replace
pump seal if necessary.
Page 40

6. Check refrigerant sight glass for air bubbles or moisture indication. If the sight glass indicates that there is a refrigeration
problem, have the unit serviced as soon as possible.
Repeat items 1 through 6 as listed above and continue with the
following.

! Once a Month
7. With the main disconnect shut off, check the condition of electrical
connections at all contactors, starters and controls. Check for loose
or frayed wires.
8. Check the incoming voltage to make sure it is within 10% of the
design voltage for the chiller.
9. Check the amp draws to each leg of the compressor and pump to
confirm that they are drawing the proper current.
Repeat items 1 through 9 listed above and continue with the
following.

! Every Three Months

10. 5 HP through 30 HP units are equipped with a Y-strainer between
the pump discharge and the evaporator inlet. The strainer basket
should be removed and cleaned if necessary. This may be required
more often if contaminants can easily get into the process water.
11. Have a qualified refrigeration technician inspect the operation of
the entire unit to ensure that everything is operating properly.
Have condenser cleaned out if necessary.

Page 41

Thermal Care Preventive Maintenance Checklist

Maintenance Activity
Date
Temperature Control
Pump Discharge Pressure
Coolant Level
Glycol Concentration
Pump Seal
Refrigerant Sight Glass
Electrical Connections
Incoming Voltage
Compressor L1 Amps
Compressor L2 Amps
Compressor L3 Amps
Pump L1 Amps
Pump L2 Amps
Pump L3 Amps
Clean Y-strainer
Refrigerant Circuit Check
Refrigerant Suction Pressure
Refrigerant Discharge Pressure
Refrigerant Superheat
Clean Out Condenser

Page 42

Week Number
6
7
8

10

11

12

13

TROUBLESHOOTING
Problem

Possible Cause

Remedy

Compressor will not

start

Compressor internal thermal

overload

Check supply voltage

Check amperages of each line
Check compressor contactor and
wiring

Compressor contactor

Replace if faulty

Microprocessor control board

Replace if faulty

Compressor failure

Contact refrigeration service

technician

Problem

Possible Cause

Remedy

Pump will not start

Pump overload

Check supply voltage

Check amperages of each line
Check overload setting
Replace overload if faulty

Pump contactor

Replace if faulty

Microprocessor control board

Replace if faulty

Pump failure

Replace if faulty

Problem

Possible Cause

Remedy

Low refrigerant
pressure

Low refrigerant charge

Contact refrigeration service

technician

Refrigerant leak

Contact refrigeration service

technician

Compressor suction service

valve partially closed

Open valve all the way

Low refrigerant pressure

control

Check for proper setting

Replace if faulty

Microprocessor control board

Replace if faulty

Page 43

Problem

Possible Cause

Remedy

High refrigerant
pressure

Dirty condenser coil (air cooled

units only)

Clean out with compressed air

Air flow obstruction (air cooled

units only)

Make sure chiller is installed in

accordance with recommendations
in this manual

High ambient air temperature

(air cooled units only)

Maximum temperature is 110F

(43C)

Condenser fan (air cooled units

only)

Replace if faulty

Condenser fan cycling controls

(air cooled units only)

Confirm proper operation

Replace if faulty

Plugged condenser (water

cooled units only)

Clean out

Insufficient condenser water

flow

Make sure chiller is installed in

accordance with recommendations
in this manual

High condenser water

temperature

Maximum temperature is 100F

(38C)

Condenser water regulating

valve

Replace if faulty

Compressor discharge service

valve partially closed

Open valve all the way

Refrigerant circuit overcharged

Contact refrigeration service

technician

High refrigerant pressure

control

Replace if faulty

Microprocessor control board

Replace if faulty

Page 44

Problem

Possible Cause

Remedy

Freezestat

Low flow through evaporator

Adjust flow to proper level

Freezestat control

Check for proper setting

Replace if faulty

Microprocessor control board

Replace if faulty

Thermocouple

Replace if faulty

Problem

Possible Cause

Remedy

Low pump discharge pressure

Pump running backwards

Switch two legs of the incoming power

No restriction in process or
piping

Slightly close off To Process

throttling valve

Pressure gauge

Replace if faulty

Pump failure

Replace if faulty

Problem

Possible Cause

Remedy

High pump
discharge pressure

Closed valves in process piping

Open valves

Closed To Process throttling

valve

Open valve

Obstruction in piping or process

Clear obstruction

Clogged Y-strainer

Clean strainer

Pressure gauge

Replace if faulty

Page 45

Problem

Possible Cause

Remedy

Insufficient cooling
(temperature
continues to rise
above set point)

Process load too high

Check to make sure chiller is

properly sized for process load

Coolant flow through evaporator too high or too low

Adjust flow to proper level

Insufficient condenser cooling

See High Refrigerant Pressure

Hot gas bypass valve stuck

open

Contact refrigeration service

technician

Refrigeration circuit problem

Contact refrigeration service

technician

Microprocessor control board

Replace if faulty

Thermocouple

Replace if faulty

Problem

Possible Cause

Remedy

Erratic temperature control

Low coolant flow through

evaporator

Adjust flow to proper level

Intermittent overloading of
chiller capacity

Check to make sure chiller is

properly sized for process load

Hot gas bypass valve

Contact refrigeration service

technician

Microprocessor control board

Replace if faulty

Thermocouple

Replace if faulty

Page 46

PUMP CURVES

Pump Pressure (PSI)

Portable Chiller
Pump Curves

Flow (GPM)
3500 RPM pumps. Curves represent pump discharge. Correct for unit discharge.
SPA-1791

Page 47

DIAGRAMS
AQ0A0H
Electrical Wiring Diagram

EWC-0767

Page 48

AQ0A01
Electrical Wiring Diagram

EWC-0771

Page 49

AQ0A02 - AQ0A10
Electrical Wiring Diagram

EWC-0731

Page 50

DIAGRAMS
AQ0W02 - AQ0W05
Electrical Wiring Diagram

EWC-0751

Page 51

AQ0W08 - AQ0W10
Electrical Wiring Diagram

EWC-0755

Page 52

AQ1W05 - AQ1W15
Electrical Wiring Diagram

EWC-0763

Page 53

AQ1W20-AQ1W30
Electrical Wiring Diagram

EWC-0884

Page 54

AQ1W35 - AQ1W40
Electrical Wiring Diagram

EWC-0894

Page 55

AIR COOLED DIMENSIONS

Air Cooled (1/2 - 3 HP)

Pressure Gauge
Electrical
Knock-Out

Sight Glass

Chilled Water Return

Chilled Water Supply

SPA-2537

Air Cooled (5 1/2 - 10 HP)

Pressure
Gauge
Electrical
Knock-Out

Chilled Water
Supply

Chilled Water
Return

SPB-2439

Page 56

WATER COOLED DIMENSIONS

Water Cooled (2 - 5 HP)

Pressure Gauge
Electrical
Knock-Out

Sight Glass
Chilled Water Return
Chilled Water Supply

Condenser Water Out

Condenser Water In

SPA-2549

Water Cooled (8 - 30 HP)

Chilled Water Supply

Chilled Water Return
Pressure
Gauge

Condenser Water Out

Condenser Water In

SPB-2550

Water Cooled (35 - 40 HP)

Condenser
Water Out
Condenser
Water In

Chilled Water Supply

Chilled Water Return

SPD-1780

Page 57

WARRANTY
Thermal Care warrants its equipment to be free from defects in material and workmanship
when used under recommended operating conditions.
Thermal Care's obligation is limited to repair (i.e. rewind a motor) or replacement (not
adjustment or maintenance), F.O.B. the factory of any parts supplied by Thermal Care for a
period of eighteen months (twelve months for 1/2 and 1 HP compressor units) from date of
shipment to the original purchaser. The microprocessor is provided with a five year parts
warranty. All units with 2 HP or larger compressors include a labor warranty in the continental United States, Canada, Puerto Rico and select portions of Mexico. Refrigerant and any
labor associated with its evacuation or replacement are not covered by this warranty.
This warranty does not cover the cost of labor during overtime hours (after normal working
hours or during weekends and holidays). Any cost differential for overtime labor will be the
responsibility of the customer. Thermal Care is not responsible for any sales, use, excise or
other applicable taxes associated with the replacement of parts under this warranty. This
warranty will be voided when, in Thermal Cares opinion, the equipment and/or system has
been subject to misuse, negligence or operation in excess of recommended limits, including
freezing, or has been altered, and/or repaired without express factory authorization. If
equipment is installed in hostile environments, unless such conditions were specified at the
time of purchase; or the serial number has been removed or defaced this warranty shall not
apply. This warranty is not transferrable.
Under no circumstances shall Thermal Care be liable for loss of prospective or speculative
profits, or special, indirect, incidental or consequential damages.
All warranty service must be authorized by Thermal Care prior to work being performed and
have a Thermal Care purchase order issued. All defective parts become the property of
Thermal Care and must be returned as advised by Thermal Care.
Thermal Care neither assumes, nor authorizes any person to assume for it, any liability not
expressed in this warranty. There is an implied warranty of merchantability and of fitness for
particular purpose; all other implied warranties, and any liability not based upon contract are
hereby disclaimed and excluded by this warranty. This warranty is part of the standard
conditions and terms of sale of Thermal Care.
Form 1-407

7720 N. Lehigh Ave.

Niles, IL 60714-3491
Phone: 847-966-2260, ext. 2900 e-mail: info@thermalcare.com
www.thermalcare.com
Fax: 847-966-9358

Page 58

Customer Service
Phone
847/966-2636
Fax
847/966-2906

Form 2-325.1
5/00