1$DCOOLFLOW CF Series manual Revised 28 Feb 1997 ======================================== Introduction ======================================== This manual is for the COOLFLOW CF series of chillers. This was the line produced before the present-day CFT series. They are quite different from a CFT and this manual only applies to the CF series. Here's how to tell them apart. Coolflow CF series CFT series Date built 1963 - May 1978 May 1978 - present Tank orientation vertical horizontal Temp control thermostatic switch electronic circuit board Solenoid valve none yes Circuit breaker on front panel none "Low Cycle lamp" on front panel none ======================================== CONTENTS ======================================== Section 1 - General Information Section 2 - Installation Section 3 - Start up Section 4 - Operating adjustments Section 5 - Maintenance Section 6 - Refrigeration Section 7 - Troubleshooting ======================================== Section 1 - General Information ======================================== 1.1 Description COOLFLOW units have been designed to provide a continuous flow of recirculated coolant. The units consist of a fabricated PVC reservoir/cooling coil assembly, a full hermetic refrigeration compressor, and a positive displacement pump. 1.2 Factory standard adjustments When shipped, the units have been adjusted to the following standards unless otherwise specified. 1.2.1 Cooling capacity: Model / Maximum cooling capacity @20C / Factory adjusted capacity @20C* CF33 / 900 watts / 600 watts CF50 / 1500 watts / 1000 watts CF75 / 2100 watts / 1400 watts * see section 4.1 for adjustment procedure 1.2.2 Maximum pump pressure - pump pressure bypass setting: 50 PSIG (345 kPa). For adjustment procedure see section 4.3. 1.2.3 Recirculation temperature limit - low cycle control: 10C. For adjustment procedure see section 4.2. ======================================== Section 2 - Installation ======================================== 2.1 Installation site Standard COOLFLOW models are air cooled. Air intake is at the front on the unit, and warm air discharge is at the rear. It is important that the unit be placed in an area where aire intake and discharge are not impeded. Lack of adequate cool air will cause a reduction in cooling capacity and/or complete shutdown of the refrigeration compressor. Excessively dusty areas should be avoided or a periodic cleaning procedure instituted (See section 5 - Maintenance). COOLFLOW units will retain their full rated capacity at air intake temperatures up to approximately 80F (27C). Higher temperatures will cause a reduction in load handling ability. Table 2.1 - approximate cool air intake Model / CFM / liters per minute CF33 / 250 / 7000 CF50 / 375 / 10600 CF75 / 565 / 16000 2.2 Plumbing COOLFLOW OUTPUT (pressure) and RETURN (suction) lines terminate at the left rear of the case. Terminations are normally 1/2" NPT. Adapters for connecting 1/2" ID flexible hose are supplied. CAUTION: In case of flow blockage, substantial pressures can be generated (See section 4.3). Flexible hose, if used, should be of heavy wall or reinforced construction. We recommend that minimum 1/2" ID lines be used to limit transmission pressure losses. If the apparatus to be cooled has smaller connections, make reductions at that point. In the case of the PD-1 (1GPM flow) pump and relatively short lines, 3/8" ID lines would be satisfactory. Lines should be as short and as straight as possible. Avoid running lines near radiators, hot water pipes, etc. If substantial lengths are necessary, thermal insulation may be required to prevent serious loss of cooling ability. Conditions that cause condensation on hoses or cooled unit should be avoided. Increasing recirculation temperature and/or low cycle setting will generally eliminate the problem. See Section 4 - Operating Adjustments. ======================================== Section 3 - Start up ======================================== 3.1 Fluids Standard COOLFLOW units are suitable for use with water, water/ethanol, and water/ethylene glycol mixtures. Use of other fluids or mixtures is not recommended and will void manufacturer's warranty. Remove top access panel. Locate tank plug (with the square nut). Remove plug. Fill reservoir with clean cooling fluid. Tank capacity is 1.1 gallons (4.1 liters). Fill to bottom of filling hole flange. Note: Tank capacity is small, compared to the volume of many systems to be cooled. Have extra fluid on hand at initial start-up, or prefill external systems. When installing COOLFLOW units on new systems, or on systems in which unfiltered tap water has been previously used, it is wise to flush the cooling circuit several times to remove rust or particles. Flushing will also help pre-fill the circuit. 3.2 Circulating coolant 3.2.1 Open systems COOLFLOW units may be used to circulate coolant to open tanks or drums. Lines are run to the external tank and secured so the return (suction) line is ALWAYS below the fluid surface. The return line must be immersed far enough to avoid sucking air. The return line must be kept free of particulate matter that might prevent return flow or cause damage to the pump. Baffle or screen if necessary. When circulating to an open system, the tank plug must be wound with Teflon sealing tape and tightened securely to prevent air entry. 3.2.2 Closed systems Pre-fill the system. Attach lines and clamp securely. Run unit briefly with tank plug removed to purge air from system. Tighten tank plug finger-tight in the absence of significant static head. If a significant static head does exist and the lines might be disconnected, seal the tank plug as in 3.2.1 to prevent flood back. ======================================== Section 4 - Operating adjustments ======================================== 4.1 Temperature adjustment (load balancing) Changes in recirculating temperature are made by increasing or decreasing the refrigerant effect of the COOLFLOW. The ability to set a given operating temperature will depend on the heat generated by the load and the rated capacity of the COOLFLOW model and environmental conditions. Table 4.1: Cooling capacity - maximum capacity and adjustment range of the three standard COOLCLOW units at 20C recirculating temperature: CF33: 300-900 watts at 20C CF50: 800-1500 watts at 20C CF75: 1400-2100 watts at 20C Note: capacity figures apply for areas where air temperature does not exceed 80F (27C). HIgher air temperatures will result in derating. 4.1.1. Remove marked panel on top of unit. Locate the refrigerant pressure adjustment valve (yellow tag). Turn the adjustable hex screw counter-clockwise to reduce the circulating temperature (increase the refrigeration effect). Turn the adjustable hex screw clockwise to increase the circulating temperature (increase the refrigeration effect). These adjustments must be made under full load conditions. Continue to make small adjustments until temperature stabilizes within a satisfactory operating zone. Without further adjustment, the COOLFLOW will maintain the set temperature under the same load conditions. However, if load increases, recirculating temperature will increase; if load decreases, so will operating temperature. 4.2 Low Cycle Control The circulating fluid is monitored by an adjustable low temperature interlock controlling the refrigeration compressor only. If the fluid temperature falls past a preset low temperature, (10C factory setting), the compressor only will shut down. This condition will be indicated by the "low cycle" light on the front panel. The pump will continue to operate and circulate fluid even with the compressor off. After a rise in circulating fluid temperature of about 3C above the low cycle setpoint, the compressor will restart. The low cycle is not meant as a temperature control, but as a limit only. The COOLFLOW operating temperature should be set by adjustment of the refrigerant pressure adjustment valve as outlined in section 4.1. 4.2.1 Low Cycle Control adjustment A. Remove marked right side (as viewed from the front) panel. B. Locate the low cycle control (temperature-actuated switch) device. C. With circulating fluid at the desired low limit, turn the adjustment on the low cycle control until the compressor just cycles "off" and the white "low cycle" lamp is lit. Allow fluid temperature to increase until compressor restarts (approximately 3C above low cycle setting). D. Remove heat load. Allow circulating fluid temperature to drop to low cycle setting. Readjust if necessary. 4.3 Pump pressure limit Standard COOLFLOW units are equipped with positive-displacement pumps of the vane type. Standard: PD-1, with 1 GPM (3.8 liter per minute) flow Optional: PD-2, with 4 GPM (15 liter per minute) flow Pumps of this design are characterized by a relatively constant delivery volume at variable delivery pressure. As resistance to flow increases, the pump generates increasing pressure to maintain delivery volume. To limit the maximum pump pressure that can be developed, an adjustable bypass valve has been installed in the pump outlet line. The factory pressure limit setting is 50 PSI. Note: Pump bypass setting does not determine actual operating pressure. It establishes a maximum limit. 4.3.1 Bypass adjustment Remove right side (as viewed from the front) access panel. Locate pressure gauge and adjacent bypass valve. Block pump flow by valving, crimping off outlet line, or installing 1/2" MPT plug in the outlet connection. The pressure gauge reading with the flow completely blocked off is the bypass pressure setting. Any adjustment in bypass pressure setting should be made with the pump outlet flow blocked. Restore pump flow through external system. Pressure gauge reading under this condition is system operating pressure. System operating pressure should be 5 - 10 PSI below the bypass pressure setting. If system operating pressure is closer than 5 PSI to bypass pressure setting, pump output flow may be split between the bypass circuit and the system. In this case, the bypass pressure setting may be raised, or the reduced system flow accepted. The final setting should be made on the basis of cooling adequacy and system pressure limits. CAUTION: Bypass pressure setting should not exceed 80 PSI (550 kPa). ======================================== Section 5 - Maintenance ======================================== 5.1 Cleaning Air-cooled COOLFLOW units pull substantial amounts of air through the front panel and across the finned refrigeration condenser. (Refer to table 2.1 in section 2). A buildup of dust or debris on the grille or condenser fins will interfere with heat transfer and prevent proper operation of the system. Normally, periodic vacuuming of the front grille will prevent loss of cooling efficiency. In severe industrial locations, it may be necessary to loosen adhering dust by brushing. It is recommended a visual inspection be made monthly after initial installation. Vacuum accumulated dust when necessary. After several months the frequency of required cleaning will be established. 5.2 Lubrication PD pumps are generally powered by sleeve-bearing "carbonator" type motors, NEMA type 48YZ*. These motors must be run on a horizontal-shaft orientation, due to the internal oil reservoir. A wick runs from the reservoir to each bearing. The motor will have either one or two lubrication ports, depending on the manufacturer. A good source of oil is the 3-IN-ONE brand squeeze cans manufactured by Boyle-Midway, Inc. It should be available at hardware stores or electrical supply houses. The motor should be oiled periodically in accordance with the nameplate directions. In the absence of legible lubrication instructions, add 30 - 35 drops of SAE 20 non-detergent oil to each oil port. Use the following table as a frequency guide: Duty Oiling frequency ------------- --------------------- Continuous Each year Intermittent Every 2 years Occasional Every 5 years Replace the plastic plug in the oil port(s) after oiling. If the plug is lost, substitute a small sheet metal screw or something similar to keep dirt out of the port. 5.3 Miscellaneous maintenance 5.3.1 Strainer Located in the pump inlet line (behind the pressure gauge) is a coarse wire mesh screen. If debris is inadvertently drawn into the pump, the screen will prevent the material from being sucked into the pump and damaging the vanes. The strainer screen may be removed for cleaning by unscrewing the hex nut. 5.3.2 Algae Most common algae and slime molds require light for growth. The construction of the CF units minimizes light entrance to the fluid when all covers are in place. When circulating to closed systems, little problem should be encountered, however, it is good practice to add some algae/bacteria inhibitor as a precaution. If circulation is to an open vessel, or if light transmitting filter containers or deionizer carti\ridges are used in the system, inhibitors are definitely recommended. NESLAB recommends the use of Chloramine-T, at the dosage rate of one gram per gallon. Chloramine-T is available from NESLAB. [======================================== Section 6 - Refrigeration ======================================== 6. 1 Coolflow CF-33 refrigerant data This applies only to systems labelled Coolflow CF-33. It does not apply to later systems designated CFT-33. Refrigerant type: R-500 Amount: 1.5 lbs (0.7 kg) Turn system on and turn the Hot gas (ADR) valve full open by turning the adjustable nut to full counter-clockwise position. With reservoir temperature at approximately 68F (20C), adjust refrigerant charge to achieve the following pressures: Suction: 35 - 50 PSIG (240 - 345 kPa) Discharge: 165 - 195 PSIG (1140 - 1345 kPa) NESLAB ONLINE document B359 Rev 17 Jan 1997 6. 2 Coolflow CF-50 refrigerant data This applies only to systems labelled Coolflow CF-50. It does not apply to later systems designated CFT-50. Refrigerant type: R-500 Amount: 2 lbs (0.9 kg) Turn system on and turn the Hot gas (ADR) valve full open by turning the adjustable nut to full counter-clockwise position. With reservoir temperature at approximately 68F (20C), adjust refrigerant charge to achieve the following pressures: Suction: 35 - 50 PSIG (240 - 345 kPa) Discharge: 165 - 195 PSIG (1140 - 1345 kPa) NESLAB ONLINE document B360 Rev 17 Jan 1997 6. 3 Coolflow CF-75 refrigerant data This applies only to systems labelled Coolflow CF-75. It does not apply to later systems designated CFT-75. Refrigerant type: R-500 Amount: 2.5 lbs (1.1 kg) Turn system on and turn the Hot gas (ADR) valve full open by turning the adjustable nut to full counter-clockwise position. With reservoir temperature at approximately 68F (20C), adjust refrigerant charge to achieve the following pressures: Suction: 35 - 50 PSIG (240 - 345 kPa) Discharge: 165 - 195 PSIG (1140 - 1345 kPa) NESLAB ONLINE document B361 Rev 17 Jan 1997 ======================================== Section 7 - Troubleshooting ======================================== Before using this checklist, be certain main power is supplied and the circuit breaker (on the front panel) is fully depressed. The circuit breaker is set (closed) when the pushbutton is flush with the surface of the bezel. The circuit breaker is tripped (open) when the pushbutton emerges from the bezel. 7.1. Inadequate cooling 7.1.1 Load too large - check heat load against CF rating or setting at temperature of circulation (Table 4.1). A. Reduce load B. Adjust temperature (Section 4.1) 7.1.2 Inadequate heat rejection to air A. Check ambient temperature. Above 80F (27C) derating will occur. B. Air intake or exhaust impeded.Unblock. C. Clean condenser fins and grille. 7.1.3 Low voltage - compressor may cycle off on interlock switch if voltage drops too low. Restore voltage to proper level. Wait 5 minutes, restart. 7.1.4 Refrigerant loss - Sight glass should be full with infrequent bubbles. A continuous stream of bubbles or empty sight glass confirms lack of refrigerant. Locate and repair leak. Recharge. (See Section 6). 7.1.5 Incorrect low cycle setting - Low cycle setting is too close to operating point, causing comrpessor to cycle off. Reset Low Cycle (Section 4.2) or Circulation Temperature Adjustment (Section 4.1). 7.2 Inadequate coolant flow 7.2.1 Insufficient pressure - Bypass valve may be opening. Check system operating pressure and bypass pressure setting,. Reset the bypass if necessary (Section 4.3). 7.2.2. Blocked pump intake line A. Check intake line (open system circulation) B. Check pump line screen (Section 5.3.1). C. In open system circulation applications, tank may not be sealed; allowing air to be drawn into tank. TIghten seal securely (Section 3.2.1). [end section 7] [end entire manual] . per gallon. Chloramine-T is available from NESLAB. [=====================================$DwDA`7e|6@`MeW|6  o#T` :dX:0gph˜D|`34h4 +hD` +,D`+,#%W13]gg!<Y[Z\uw "NP79;e O Q z |  X Z YWY35_uvxBD Y[ ,.DFE576UW&GIqs!# +!-!t!v!u""""####x#z####$p%r%%%%%&1'3'3'''\(^(U)W))))*+*D*n*p*~**%+'++++h,j,2-4-E-G-F...1/3/*0,0H0p0000000u1w11111222223,4.444X5Z55555555+6b6d6}6666U7777778888;8=8t888888A99999*:,:I:Z:\::::::: ;';);;;<<F<s<u<<<<<<===>K>M>O>h>j>>>>>??>?@????????r@t@GAIABB4B6BBBCC3C5CaCcCCCDDDD D"D$D&DB4B6BBBCC3C5CaCcCCCDD Arial 4.1) 7.1.2 Inadequate heat rejection to air A. Check ambient temperature. Above 80F (27C) derating will oc