Conair Refrigerator 025 to 15 ton User Manual

Portable Chillers  
VL Series, 0.25 to 1.5 ton models  
Installation  
Maintenance  
Operation  
Troubleshooting  
The Conair Group, Inc.  
Instant Access  
Parts and Service  
(800) 458-1960  
One Conair Drive  
Pittsburgh, PA 15202  
Phone: (412) 312-6000  
Fax: (412)-312-6227  
(814) 437-6861  
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TABLE OF CONTENTS  
1.0  
GENERAL  
5
6
6
6
6
7
1.1  
1.2  
1.3  
1.4  
1.5  
Unit location  
Efficiency  
Safety  
Clean air act  
Miscellaneous  
2.0  
INSTALLATION  
9
2.1  
2.2  
2.3  
2.4  
2.5  
General  
10  
10  
11  
11  
12  
To and From process connections  
Unit drain  
Air-cooled condenser  
Electrical connection  
3.0  
4.0  
OPERATIONS SEQUENCE  
13  
14  
14  
15  
18  
3.1  
3.2  
3.3  
3.4  
General  
Start up / operations procedure  
Instrument operation  
Shut down / disconnect sequence  
TROUBLESHOOTING  
19  
20  
20  
20  
20  
20  
4.1  
4.2  
4.3  
4.4  
4.5  
Unit will not start  
Pump will not start  
Compressor will not start  
Unit shuts down on high pressure switch  
Unit shuts down on low pressure switch  
5.0  
MAINTENANCE  
23  
24  
24  
25  
25  
5.1  
5.2  
5.3  
5.4  
Warranty service procedure  
Periodic preventative maintenance  
Special maintenance  
Pump repair  
6.0  
7.0  
8.0  
COMPONENTS  
27  
28  
28  
6.1  
Water system  
6.2  
Refrigeration system  
RELATED DRAWINGS  
29  
30  
31  
7.1  
Electrical (typical)  
7.2  
Circuit schematic  
APPENDIX  
33  
34  
35  
37  
37  
39  
40  
41  
42  
8.1  
8.2  
8.3  
8.4  
8.5  
8.6  
8.7  
8.8  
Specifications  
Operations below 48°F  
Water quality control  
Inhibited propylene glycol  
Chiller capacity and derate chart  
Pressure - temperature chart for R-22  
Engineering formulas  
Spare parts list  
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1.0  
GENERAL  
1.1  
1.2  
1.3  
1.4  
1.5  
UNIT LOCATION  
EFFICIENCY  
SAFETY  
CLEAN AIR ACT  
MISCELLANEOUS  
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1.1  
UNIT LOCATION  
A.  
The unit is designed for indoor use only. For most efficient  
operation, locate the chiller in a clean, dry and well ventilated  
environment.  
B.  
The unit has an air-cooled refrigerant condenser. For air-cooled  
condensers, a motor driven fan generates air flow through the  
condenser to remove heat from the refrigerant system. The air-  
cooled condenser on the unit will discharge a maximum of 15,000  
BTUs per hour per ton of cooling.  
C.  
The unit must have a minimum entering air temperature of 60°F  
and a maximum entering air temperature of 95°F for efficient  
operation.  
D.  
E.  
The unit must have a minimum of two feet clearance at the air  
intake and six feet at the exhaust air discharge.  
If the operator has any questions concerning the location and  
operation of the unit, contact the Conair service department at  
800-458-1960.  
1.2  
1.3  
1.4  
EFFICIENCY  
A.  
Long term efficiency of operation is largely determined by proper  
maintenance of the mechanical parts of the unit and the water  
quality. Conair recommends filtering where required to prevent  
solids from plugging critical parts (pumps, heaters, seals for  
example). Conair highly recommends the services of a competent  
water treatment specialist be obtained and his recommendations  
followed. Conair accepts no responsibility for inefficient operation,  
or damage caused by foreign materials or failure to use adequate  
water treatment.  
SAFETY  
A.  
It is important to become thoroughly familiar with this manual and  
the operating characteristics of the unit.  
B.  
C.  
It is the owner’s responsibility to assure proper operator training,  
installation, operation, and maintenance of the unit.  
Observe all warning and safety placards applied to the unit. Failure  
to observe all warnings can result in serious injury or death to the  
operator and sever mechanical damage to the unit.  
CLEAN AIR ACT  
A. The unit contains HCFC-22 (chlorodifloromethane). This is a class 2  
substance.  
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B.  
C.  
Please be aware that effective July 1, 1992, it is unlawful for any  
person in the course of maintaining, servicing, repairing, or  
disposing of refrigeration equipment to knowingly vent or  
otherwise dispose of any class 2 substance used as a refrigerant in  
the manner which permits such substance to enter the  
environment.  
De minimis releases associated with good faith attempts to  
recapture, reclaim, or recycle such substance shall not be subject to  
the prohibition set forth in the preceding paragraph.  
1.5  
MISCELLANEOUS  
A.  
B.  
C.  
The purpose of the unit is to circulate temperature stabilized fluid  
through your process, resulting in process temperature control.  
The ability of the unit to maintain process temperature control is  
significantly affected by the method of installation.  
If the operator has any questions concerning the location and  
operation of the unit, please contact the Conair service at  
800-458-1960 or 814-437-6861  
Electrical Panel  
Reservoir  
Illuminated ‘On’ Switch  
Controller  
Bypass Valve  
Thermocouple  
Pump  
Refrigerant  
Sight Glass  
Filter-Drier  
Air Cooled Condenser  
Condensing Fan  
Refrigerant  
Safety Switches  
Power Cord  
Liquid Receiver  
Caster  
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2.0  
INSTALLATION  
2.1  
2.2  
2.3  
2.4  
2.5  
GENERAL  
TO AND FROM PROCESS CONNECTIONS  
UNIT DRAIN  
AIR COOLED CONDENSER  
ELECTRICAL CONNECTION  
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2.1  
GENERAL  
A.  
All process piping materials (such as hose, rigid piping, valves or  
filters) used in process water piping circuitry must be rated for  
100°F minimum temperature and 100 PSI minimum pressure.  
B.  
All such materials must have the equivalent or larger diameter of  
the particular process connection that length of process water  
piping is connected to.  
From process connection:  
connect to “water out” on process manifold  
To process connection:  
connect to “water in” on process manifold  
2.2  
TO AND FROM PROCESS CONNECTIONS  
A.  
B.  
C.  
Connect the chiller’s “to process” connection to the “water in”  
manifold on the mold or process.  
Connect the chiller’s “from process” connection the “water out”  
manifold at the mold or process.  
Process water piping circuitry should be designed to avoid an  
excessive use of elbows and/or lengths of pipe or hose. If hose is  
the material of choice, avoid tight twists or curls and excessive  
lengths.  
D.  
Valves and filters may be installed in the process water piping  
circuitry to facilitate service and maintenance provided that such  
devices maintain the full inside diameter of the process connection.  
If installed, all such devices must be open and clean during unit  
operation.  
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2.3  
DRAIN CONNECTION:  
A.  
The unit is supplied as standard with a ProCon type pump. In some  
cases, it may be necessary to drain the unit. This is done by  
removing the pump volute plug in the pump assembly.  
B.  
C.  
Note that if chemical treatment of process fluid or additives are use,  
drainage shall be done according to local codes.  
It is important to note that drainage procedures must be done prior  
to shipment or outdoor storage or the unit. If not, freezing damage  
can occur.  
Motor  
Thermocouple  
Pump  
Drain plug  
2.4  
AIR COOLED CONDENSER  
A.  
Air-cooled condenser require ambient air temperatures between  
60°F and 95°F for efficient operation. Operating above 95°F may  
result in elevated condensing pressures and eventual shut-down on  
the high pressure safety switch. Check with the Conair service  
department for more information on operating with ambient air  
temperatures above 95°F or below 60°F.  
B.  
Air flow is generated by the motor driven fan. Air flow is from the  
outside of the chiller, through the condenser and exhausted  
through the unit. Exhaust air can not be ducted on motor driven  
fan models.  
C.  
D.  
A free air space of at least four (4) feet is required at the condenser  
intake and four (4) feet at the condenser discharge to allow for  
proper air flow.  
At full load, this chiller will discharge approximately 15,000 BTU/hr  
per hour per ton of cooling.  
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2.5  
ELECTRICAL CONNECTION  
A.  
NEMA 1 MODELS  
1. Electrical power supply requirements for Nema 1 units  
(figure 2.5A) are identified on the equipment data plate.  
Verify that available voltage supply is the same as the unit’s  
voltage requirements. WARNING: Do not connect the  
unit to a voltage supply source not equal to the unit’s  
voltage requirements as specified on the unit’s data  
plate. Use of incorrect voltage will void the unit’s  
warranty and cause a significant hazard that may result  
in serious personal injury and unit damage.  
2.  
A factory supplied, four conductor cable is installed for  
connection to a customer supplied fused power disconnect  
device. The fused disconnect device shall be sized and  
installed according to the unit’s power supply requirements  
and local electrical codes.  
C.  
D.  
CONTROL CIRCUIT WIRING  
1. The unit’s supplied control circuit is indicated in the  
electrical diagrams. The control circuit is supplied by the  
factory installed transformer.  
GENERAL  
1.  
Make certain all ground connections to the unit are  
properly affixed.  
2.  
Make certain power conductor, disconnect device, and  
fusing are properly sized according to the unit’s power  
supply requirements.  
3.  
4.  
Make certain all electrical connections are tightly affixed.  
Any loose wiring connections must be tighten before  
engaging the power supply.  
Make certain no moisture or standing water is present  
inside the electrical cabinet.  
Illuminated on/off  
switch  
Microprocessor  
controller  
Transformer  
Motor starter  
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3.0  
OPERATIONS  
3.1  
3.2  
3.3  
3.4  
GENERAL  
START UP/OPERATIONS PROCEDURE  
INSTRUMENT OPERATION  
SHUT DOWN/DISCONNECT SEQUENCE  
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3.1  
GENERAL  
A.  
Failure to follow the factory required operation procedures may  
adversely affect the unit’s ability to control process temperature and  
may create a hazardous operating condition which may result in  
unit damage and serious operator injury or death.  
B.  
The Operations segment of this manual is outlined below:  
3.2  
Machine start-up/operations procedure - follow this  
segment to start the unit after the initial installation or to  
restart the unit after reinstallation to the same or different  
process. This section includes information on system fill,  
electric motor phasing (pump rotation) and process flow  
adjustments.  
3.3  
3.4  
Instrument - follow this segment to start up and operate  
the instrument controller. This section includes information  
on automatic and manual venting, setpoint selection and  
adjustment, and feature explanations.  
Shut down procedure - follow this segment to shut down  
the unit. This segment includes information on system cool  
down, shut down, electrical power supply precautions, and  
disconnection from system.  
3.2  
START UP/OPERATIONS PROCEDURE  
A. SYSTEM FILL  
1.  
The unit has an internal reservoir which must be filled and  
maintained for proper operation.  
2.  
Conair recommends the addition of 20% inhibited  
propylene glycol to the process fluid. This should help  
prevent the process fluid from freezing and internal  
components from rusting. A biocide must be added to the  
water to prevent organism growth in the chilled water  
system. See water treatment section in section 8 of this  
manual for more information.  
3.  
Remove the top panel  
to access the reservoir.  
Add fluid directly to the  
reservoir tank. Please  
note, when the pump is  
first started, and after  
the process lines are  
filled and entrained air  
is purged, additional  
fluid may be required to  
restore the reservoir to  
Reservoir  
the correct level.  
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B.  
OPERATIONS  
1.  
2.  
Turn the thermostat to the highest setting.  
Shift the illuminated toggle switch to the ‘ON’ position.  
The pump will begin operations. Note the reservoir level, if  
it drops below 3/4 full, add fluid.  
3.  
Check the unit and process system for leaks. Repair any that  
are discovered.  
4.  
5.  
Adjust the setpoint thermostat as required for the process.  
Note, the compressor will start if the fluid temperature is  
above the selected setpoint temperature. When the  
compressor starts, listen for any knocking or other unusual  
noise. Report any unusual noise to the Service department  
and discontinue operations.  
6.  
7.  
Do not operate the unit without all sheet metal enclosure  
panels secured.  
Process flow is adjusted according to the pump motor  
amperage. This rating can be found on the pump motor  
data plate.  
a.  
With all process valves fully open and with the  
pump motor operating, check amp draw with an  
amp meter and note findings.  
b.  
Compare amp draw with pump motor rating. If  
excessive, partially close the from process valve to  
adjust motor amps.  
3.3  
INSTRUMENT OPERATION  
A. GENERAL DESCRIPTION  
A.  
The EWPC 902/T/R/P controller is a new series of  
microprocessor-based and fully programmable process  
controllers for single point applications.  
B.  
The front keypad of this controller offers several alpha-  
numeric menu prompts to configure the controller for each  
specific application).  
B.  
FRONT KEYPAD  
1.  
SET: push to display the setpoint value. The setpoint can be  
changed by using the “up” or “down” button. The control  
will automatically switch back to normal operating mode  
within 3 seconds. The last entered setpoint will stay in  
memory.  
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Output Status Light  
Set Button  
Up Arrow  
UP  
Press for less than  
3 seconds to change  
setpoint.  
out  
DOWN  
Down Arrow  
SET  
ewpc902t  
Press for more than  
4 seconds to access  
parameters.  
2.  
UP: used to increase the setpoint value, as well as the  
parameter when in programming. When held down for a  
few seconds, the change rate accelerates.  
3.  
4.  
DOWN: used to decrease the setpoint value, as well as the  
parameter when in programming. When held down for a  
few seconds, the change rate accelerates.  
OUT: status light of the output, blinks when in setpoint  
display/change mode or during programming.  
C.  
DESCRIPTION OF PARAMETERS  
1.  
D1: setpoint differential. The switching differential  
(hysteresis) can be set with positive value (make on rise) or  
with negative value (make on fall). See parameter “HC1”.  
2.  
LS1: lower set. This is the lower limit below which the user  
cannot change the setpoint; normally set at the lowest  
value recommended for the sensor.  
3
HS1: higher set. Similar to “LS1”, however setting an upper  
limit for the setpoint.  
4.  
od: output delay. This provides a delay selection for the  
outputs in applications where noise may cause brief  
erroneous signals from the sensor to the controller. Factory  
set at “0”.  
5.  
6.  
7.  
Lci: lower current input (for EWPC 902/R, EWPC 902/P and  
EWPC 902/T with current input only). Read-out  
corresponding to 4 mA input signal (factory set at 20 %R.H  
for EWPC 902/R).  
Hci: high current input (for EWPC 902/R, EWPC 902/P and  
EWPC 902/T with current input only). Read-out  
corresponding to 20 mA input signal (factory set at 100  
%R.H for EWPC 902/R).  
CAL: CALibration. This offers an adjustment up or down of  
the read-out, if needed. Factory set at “0”.  
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8.  
PSE: Probe SElection. Input type (for RTD or Thermocouples  
only). RTD models: Ni = Ni100; Pt = Pt100. T/C models: FE  
= TcJ; Cr = TcK; rh = TcS.  
9.  
HC1: Heating/Cooling. Relay switch function. H = heating  
(humidification; reverse action); C = cooling  
(dehumidification; direct action).  
10.  
11.  
rP1: relay Protection 1. Determines the status of the relay in  
case of sensor defect. Factory set at “ro”. ro = relay open;  
rc = relay closed.  
LF1: Led Function 1. Determines whether the status light in  
ON or OFF in relation to output 1. di = direct = light ON  
when output 1 is energized; in = reverse = light OFF when  
output 1 is energized.  
12.  
13.  
dP: decimal Point. Choose whether the resolution is  
required with or without decimal point. oF = without  
decimal point; on = with decimal point.  
Notes: (a) the decimal point of models with current or  
voltage input is shifted: the actual value of parameters “Lci”  
and “Hci” must be multiplied by 10. (b) On all versions, if a  
unit is changed from without decimal point to with decimal  
point, all parameter values expressed in degrees will  
automatically be divided by 10, including the setpoint! (c)  
The decimal point selection is not available on models for  
thermocouple input.  
14.  
15.  
hdd: half digit display. The right-most digit can be set to  
read-out in 0 or 5 only, or in all 10 digits. hdd = n : e.g.  
070, 071, 072 etc (if without decimal point) or 70.0, 70.1,  
70.2 etc (if with decimal point.); hdd = y : e.g. 070, 075,  
080, etc. (if without decimal point) or 70.0, 70.5, 80.0 etc,  
(if with decimal point). Useful when measuring values  
varying rapidly (e.g. %R.H.)  
tAb: tAble of parameters. This shows the configuration of  
the parameters as set in the factory; can not be modified  
(for factory identification and diagnostic purposes only).  
D.  
PARAMETERS DEFAULTS  
1.  
2.  
Programming is easily accessed by holding the “SET”  
button down for more than 4 seconds.  
The first parameter is displayed while the status light Led  
“out” remains blinking during the programming period.  
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DEFAULT SETTING - STANDARD MODLES  
PARAMETER  
DECRIPTION  
RANGE  
min / max  
min / max  
min / max  
min / max  
min / max  
min / max  
min / max  
Ni / Pt / Fe / Cr / rh  
H / C  
UNIT  
FACTORY  
d1  
differential  
C /  
C /  
C /  
F
4
40  
70  
60  
0
LS1  
HS1  
od  
Lower Set  
F
F
Higher Set  
output delay  
seconds  
various  
various  
Lci  
Low current input  
High current input  
CALibration  
Hci  
0
CAL  
PSE  
HC1  
rP1  
C /  
/
F
0
Probe SElection  
Heating / Cooling  
relay Protection  
Led Function  
Fe  
C
flag  
flag  
flag  
flag  
flag  
flag  
ro / rc  
RO  
OF  
N
LF1  
di / in  
dp  
decimal Point  
half digit display  
tAble of parameter  
on / oF  
hdd  
n / y  
tAb  
/
3.  
4.  
Other parameters are accessed with the “UP” and “DOWN”  
button. With the “SET” button, the actual setting of each  
parameter is displayed. To change a parameter setting,  
push the “SET” plus the “UP” (or “DOWN”).  
The system will automatically return to its normal operating  
mode a few seconds after the programming procedure is  
completed or interrupted.  
E.  
ERROR ANNUNCIATION  
1.  
Any sensor input defect will be displayed as follows: “ - - - ”  
in case of shorted sensor - EEE; in case of sensor break or  
sensor absence. The EEEerror message also appears in  
the event of overrange of underrange of the system  
temperature.  
2.  
It is recommended to double check the sensor wiring  
before diagnosing a probe as defective.  
3.4  
SHUT DOWN/DISCONNECT SEQUENCE  
A.  
PRECAUTIONS/WARNINGS  
1. The operator must precisely follow all shut down  
procedures outlined in this manual. If the operator fails to  
do so, an unsafe condition can develop resulting in damage  
to the unit or injury and/or death to operating personnel.  
B.  
UNIT SHUT DOWN (without system disconnect)  
1.  
To shut down the unit: toggle ‘off’ the rocker switch and  
disconnect the electrical supply.  
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4.0  
TROUBLESHOOTING  
4.1  
4.2  
4.3  
4.4  
4.5  
UNIT WILL NOT START  
PUMP WILL NOT START  
COMPRESSOR WILL NOT START  
UNIT SHUTS DOWN ON HIGH PRESSURE SWITCH  
UNITS SHUTS DOWN ON LOW PRESSURE SWITCH  
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4.1  
4.2  
UNIT WILL NOT START  
A.  
B.  
Blow fuse at power supply - isolate open fuse and replace. Double  
check fuse sizes against nameplate amperage.  
Low voltage - measure incoming voltage with meter, voltage must  
be within 10% of nameplate voltage or warranty will be voided.  
PUMP WILL NOT START  
A.  
B.  
C.  
D.  
E.  
Impeller bound or frozen shaft bearing in motor.  
Open motor winding.  
Internal overload tripped.  
Loose wire connection or defective start capacitor.  
On/off circuit breaker tripped.  
4.3  
COMPRESSOR WILL NOT START  
A.  
B.  
C.  
Safety switch open - unsafe condition exists (consult safety switch  
section in this manual).  
Windings overheated - over temperature switch on compressor  
tripped.  
Circuit breaker tripped - reset and check amperage. Verify voltage is  
correct, check for loose wire connection at motor. Defective circuit  
breaker.  
D.  
Bad or defective start capacitor.  
4.4  
UNIT SHUTS DOWN ON HIGH PRESSURE SWITCH  
A.  
B.  
Low air flow across condenser. Check for dirty condenser fins.  
Fan not operating. Check for loose fan blade or open/grounded  
motor winding.  
C.  
D.  
High ambient air temperature (above 95°F).  
Insufficient clear space around unit.  
4.5  
UNIT SHUTS DOWN ON LOW PRESSURE SWITCH  
A.  
B.  
Attempting to operate below 40°F.  
Low refrigerant charge.  
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C.  
D.  
Restriction to refrigerant flow in refrigeration circuit.  
Poor heat transfer in evaporator tank because (1) percentage of  
glycol to water is too high and (2) scaled tubes in evaporator tank  
(chemically descale).  
E.  
Low flow through evaporator tank due to (1) process flow restricted  
or (2) glycol foaming.  
Page: 21  
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5.0  
MAINTENANCE  
5.1  
5.2  
5.3  
5.4  
WARRANTY SERVICE PROCEDURE  
PERIODIC PREVENTATIVE MAINTENANCE  
SPECIAL MAINTENANCE  
PUMP REPAIR  
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5.1  
WARRANTY SERVICE PROCEDURE  
A.  
In the event of a problem with a chiller that can not be resolved by  
normal troubleshooting procedures, the customer is invited to  
consult the Conair service department for assistance. The correct  
model number and serial number of the chiller must be available.  
The service department will attempt to isolate the problem and  
advise repair procedures. Often times, with the customer’s input  
and with the machine diagnostics, problems can be determined  
with “over-the-phone” consultation.  
B.  
C.  
If the problem is beyond the scope of “over-the-phone”  
consultation, and if the warranty status of the machine is valid,  
Conair will contact the nearest authorized service contractor and  
provide authorization to conduct an “on-site” inspection of the unit  
in order to determine the course of repair. If the chiller is not  
covered by the warranty, Conair will advise on the repair and  
recommend available service contractors.  
Conair manufactures a complete line of heat transfer equipment. It  
is of the utmost importance that Conair have the correct model  
number and serial number of the machine in question. This will  
allow Conair to obtain the correct manufacturing records which  
will help the service department to properly troubleshoot the  
problem and obtain the proper replacement parts when they are  
required. This information is stamped on the metal data tag that is  
attached to the machine.  
D.  
The Conair service department must be notified prior to any repair  
or service of a warranty nature. Warranty claims will not be honored  
without prior authorization.  
5.2  
PERIODIC PREVENTATIVE MAINTENANCE  
A.  
Lubricate all motors. Note that some motors are supplied with  
sealed bearings.  
B.  
C.  
D.  
E.  
Tighten all wire terminals.  
Clean and check motor starter and contactor contacts.  
Check safety switch settings.  
Clean condenser fins of dust and dirt.  
Back flush evaporator.  
F.  
G.  
H.  
Check glycol/water solution ratio for operating temperature.  
Check system for leaks.  
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I.  
J.  
Refrigerant sight glass: check for bubbles when compressor is  
operating at 100%. Check the moisture indicator for a color other  
than green.  
Clean unit.  
5.3  
SPECIAL MAINTENANCE  
A.  
Any service of the refrigeration system must be accomplished by a  
certified refrigeration technician.  
1.  
2.  
3.  
4.  
5.  
6.  
7.  
8.  
Vacuum check compressor.  
Addition of compressor oil.  
Addition of refrigerant.  
Repair of a refrigerant leak.  
Adjustment of super heat.  
Changing of filter-drier or drier core.  
Repair of a refrigeration solenoid.  
Valve plate replacement on compressor.  
5.4  
PUMP REPAIR  
A.  
The positive displacement pump in the unit is not field serviceable.  
To arrange for repair contact:  
PROCON PUMPS  
910 RIDGELY ROAD  
MURFEESBORO, TN 37310  
615-890-5710  
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6.0  
COMPONENTS  
6.1  
WATER SYSTEM  
6.2  
REFRIGERATION SYSTEM  
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6.1  
6.2  
WATER SYSTEM  
A. MOTOR/PUMP ASSEMBLY: the motor/pump assembly  
circulates chilled fluid to the process loop. The pump assembly is  
built of brass to maintain water quality.  
REFRIGERATION SYSTEM  
A.  
COMPRESSOR: hermetic compressors take low pressure/low  
temperature refrigerant gas and compress the gas into high  
pressure/high temperature gas).  
B.  
AIR COOLED CONDENSER: the air cooled condenser removes  
BTUs from the compressor refrigerant gas. The action causes the  
gas to “condense” into a liquid state still under high pressure. Air  
flow across the condenser is achieved via a motor driven fan.  
C.  
D.  
E.  
FILTER-DRIER: the filter-drier removes contaminants and  
moisture from the liquid refrigerant.  
LIQUID RECEIVER: serves as a collection tank for high pressure  
liquid refrigerant to ensure total charge at all times.  
REFRIGERANT SIGHT GLASS: the refrigerant sight glass  
indicates refrigerant charge and moisture content. Refrigerant  
charge is determined by a clear liquid flow. Bubbles indicate low  
refrigerant. Moisture content is indicated by the color of the  
element. Element color is normally green. If the color of the  
element is chartreuse or yellow, the system has been  
contaminated with moisture. In such case, the filter-drier must  
be replaced. The replacement of the filter-drier must be  
completed by a qualified refrigerant service technician.  
F.  
EXPANSION VALVE: the expansion valve throttles flow of  
refrigerant liquid into the evaporator and creates a pressure drop  
in the refrigerant system that allows the liquid refrigerant to “boil  
off” inside the evaporator.  
G.  
H.  
EVAPORATOR: the evaporator is a tube in tube heat exchanger  
where the refrigerant liquid is allowed to evaporate (boil off) to  
absorb heat (BTU) from the process fluid. As the heat is  
absorbed, the process fluid is chilled.  
HIGH/LOW PRESSURESTATS: the high/low pressurestats protect  
the refrigeration system from unsafe operating levels. The high  
pressure switch is factory set to open at 325 psi and protects  
the refrigeration components and personnel from potential  
damage of injury from excessive high pressure. The high pressure  
safety must not be altered in the field for any reason. The low  
pressure switch is factory set to open at 58 psi and to close at  
63 psi. The low pressure switch protects the chillers from  
possible damage due to low operating pressure. The low  
pressure switch is field adjustable for setpoints below 48°F.  
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7.0  
RELATED DRAWINGS  
7.1  
ELECTRICAL DRAWING (TYPICAL)  
7.2  
CIRCUIT SCHEMATIC  
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7.1  
ELECTRICAL DRAWING (TYPICAL)  
UNIT  
ON/OFF  
1
5
5
2
6
6
POWER ENTRY  
230/1/60  
GREEN  
GREEN  
GREEN  
230/1/60  
PRIMARY  
RELAY  
2
4
2
4
24 VAC  
SECONDARY  
8
6
11  
1
0
BLU  
BLU  
7
5
6
8
1
5
M1  
PUMP  
4
2
9
3
3
10  
TYPE "J"  
THERMOCOUPLE  
7
8
9
10  
9
4
6
7
8
10  
5
ELIWELL  
902T  
C
R
1
3
13  
CONDENSING  
UNIT  
DUAL HIGH-LOW  
PRESSURESTAT  
11  
11  
13  
11  
11  
5
5
5
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7.2  
CIRCUIT SCHEMATIC  
2
11  
10  
12  
1
3
7
9
8
4
5
6
ITEM DESCRIPTION  
1
2
3
4
5
6
7
8
9
Compressor  
Air cooled condenser  
Liquid receiver  
Filter-drier  
Refrigerant sight glass  
Expansion valve  
Evaporator  
Pump  
To process connection  
10 From process connection  
11 Reservoir tank  
12 Refrigerant safety switch  
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8.0  
APPENDIX  
8.1  
8.2  
8.3  
8.4  
8.5  
8.6  
8.7  
8.8  
SPECIFICATIONS  
OPERATION BELOW 45°F  
WATER QUALITY CONTROL  
INHIBITED PROPYLENE GLYCOL  
CHILLER CAPACITY AND DERATE CHART  
PRESSURE - TEMPERATURE CHART FOR R-22 REFRIGERANT  
ENGINEERING FORMULAS  
SPARE PARTS LIST  
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8.1  
SPECIFICATIONS  
VL Air-cooled Portable Chillers: 0.25 to 1.5 tons  
MODEL  
VLA-.25  
VLA-.33  
VLA-.5  
VLA-.75  
VLA-1  
VLA-1.5  
Performance characteristics  
Capacity* tons  
Compressor Hp {kW}  
0.25  
0.32  
0.41  
0.5 {0.37}  
0.25 {0.19} 0.25 {0.19}  
0.9 {3.4}  
60 {4.1}  
4 {15}  
0.70  
0.75 {0.56}  
0.98  
1.35  
0.25 {0.19}  
0.25 {0.19}  
0.6 {2.3}  
0.33 {0.25}  
0.25 {0.19}  
0.8 {3.0}  
60 {4.1}  
1 {0.75}  
0.5 {0.37}  
2.4 {9.1}  
60 {4.1}  
4 {15}  
1.5 {1.1}  
0.5 {0.37}  
3.6 {13.6}  
60 {4.1}  
4 {15}  
Pump Hp {kW}  
Chilled water flow gpm {lpm}  
Chilled water pressure psi {bar} 60 {4.1}  
1.7 {6.4}  
60 {4.1}  
4 {15}  
Reservoir capacity gal {liters}  
Dimensions in {mm}  
Height  
Width  
Depth  
4 {15}  
4 {15}  
33 {838}  
18 {457}  
24 {610}  
33 {838}  
18 {457}  
24 {610}  
33 {838}  
18 {457}  
24 {610}  
33 {838}  
18 {457}  
24 {610}  
33 {838}  
18 {457}  
24 {610}  
37 {940}  
19 {483}  
25 {635}  
Pipe size NPT in.  
Process (to and from)  
Condenser  
0.5  
0.5  
0.5  
0.5  
0.5  
0.75  
Weight lb {kg}  
§
Shipping  
150 {68}  
150 {68}  
170 {77}  
205 {93}  
210 {95}  
220 {100}  
Voltages full load amps**  
115V/1 phase/60Hz  
220V/1 phase/60Hz  
Refrigerant  
11  
12  
14  
8
HCFC-22  
22  
11  
24  
12  
15  
SPECIFICATION NOTES  
* Ton capacity at 12,000 BTU/ton @ 50°F leaving water temperature @ 115°F condensing temperature. Capacities  
may be 5% as reserved by the compressor manufacturer. Capacity multipliers are: 50°F - 1.00; 40°F - 0.80;  
30°F - 0.60; 20°F - 0.40.  
Hermetic reciprocating compressor.  
Consult pump curve for exact characteristics relating to pump performances.  
Unit weight crated for shipment  
§
** No allowance for inrush. Service disconnect by owner. Full load amps must be used to size disconnects and  
supply conductors. Consult factory for 50hz operation.  
Specifications can change at any time. Contact your Conair representative for the most current information.  
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8.2  
OPERATION BELOW 48°F  
A.  
A chiller typically operates with a setpoint of 50°F or higher.  
However, if setpoints between 20° - 48°F are required, special  
precautions must be taken to prevent freezing and possible  
damage. Attention must be given to freeze protection, water supply  
and safety adjustments.  
B.  
FREEZE PROTECTION  
1.  
It is understood that untreated water freezes at 32°F.  
Therefore, an inhibited propylene glycol and water solution  
must be used in lieu of ordinary water. Prescribed amounts  
are listed in figure 8.2A.  
OPERATING  
ANTI-FREEZE MIXTURE  
TEMPERATURE  
GLYCOL  
WATER  
40°F  
25°F  
30°F  
20%  
25%  
30%  
80%  
75%  
70%  
Figure 8.2A  
2.  
On initial installation of the unit, the water/glycol solution  
should be premixed, then added to the reservoir. After the  
pump has been started, water lines filled and air purged, it  
may be necessary to add more water/glycol solution to  
maintain the recommended reservoir level. Note: a  
hygrometer should be used on a regular basis to determine  
the mixture strength according to freeze point. The freeze  
point temperature should be 25° below the lowest required  
setpoint. Water will evaporate from the mixture, and if you  
continue to add a premixed solution eventually you will  
have too much glycol. It is necessary to add water or glycol  
to maintain proper freeze point temperature.  
3.  
PLEASE NOTE THAT A CHILLER IS NOT DESIGNED TO  
ACCOMMODATE AUTOMOTIVE TYPE ANTI-FREEZE. This  
is due to the fact that automotive type anti-freeze contains  
silicates that adhere to heat transfer surfaces of the system  
preventing maximum heat transfer. Also, improper portions  
of inhibited propylene glycol to water inhibits effective heat  
transfer. Consult the chiller’s operating manual for specific  
details.  
C.  
WATER SUPPLY  
1.  
The automatic water supply (if equipped) restores the  
reservoir water level as needed. However, if untreated water  
is added to an water/glycol solution, dilution will occur  
decreasing the freeze protecting ability of the solution.  
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Therefore, the water supply source must be disconnected  
and the connection capped. The operator must monitor the  
water/glycol level and manually make-up to maintain  
proper reservoir level.  
D.  
SAFETY ADJUSTMENTS  
1.  
To ensure safe and efficient operations at lower setpoints,  
adjustments of the freezestat and low pressurestat factory  
settings are required. Figure 8.2B lists the appropriate  
settings.  
Figure 8.2B  
2.  
3.  
The freezestat serves as the mainline defense  
against freezing in that it shuts down the chiller if the  
coolant temperature ever decreases to its setting. For  
mechanical freezestats, adjustments are made by removing  
the cover and rotating the selector dial with a screwdriver.  
Electronic freezestats are adjusted through the setup  
parameters via the instrument control panel.  
The low pressurestat serves to protect the compressor from  
unsafe suction pressures. Suction pressures decrease with  
lower operating setpoints. To prevent short cycling of the  
compressor, the low pressurestat must be adjusted to  
accommodate the lower setpoint. Adjustments to the low  
pressurestat are made by rotating the adjusting screws on  
top of the control and observing the movement of the  
pointers in the control window until the prescribed setting  
is determined.  
E.  
PRECAUTIONS  
1. At any setpoint, the possibility of freezing exists and it is the  
operator’s responsibility to take necessary action to prevent  
freezing at all times.  
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8.3  
WATER QUALITY CONTROL  
A.  
Lack of, as well as, improper water treatment can damage the  
chilling unit. The services of a competent water treatment specialist  
should be obtained and their recommendations followed. It is the  
equipment owner’s responsibility to prevent damage from foreign  
material or inadequate water treatment.  
B.  
The two main things to consider for water treatment in chillers are  
corrosion and organism growth. Proper chemical treatment can  
control PH levels and algae growth. An alternative to chemical  
treatment is the addition of 20% inhibited propylene glycol to the  
water. This will help prevent organism growth and coat the heat  
transfer surfaces with corrosion inhibitor.  
8.4  
INHIBITED PROPYLENE GLYCOL  
FREEZING POINTS FOR  
WATER/PROPYLENE GLYCOL SOLUTIONS  
A.  
The use of a water-glycol  
mixture is needed when  
the operator desires a  
process temperature  
PERCENTAGE OF  
GLYCOL* WATER  
FREEZE POINT  
˚F  
˚C  
0
100  
90  
80  
70  
60  
50  
40  
32  
25  
10  
0
0
-3.9  
-12.2  
-17.8  
below 48°F. Freeze  
10  
20  
30  
40  
50  
60  
protection is required so  
ice crystals do not form  
and cause severe damage  
to both the water and  
refrigeration system.  
-10 -23.3  
-30 -34.4  
-60 -51.4  
*PROPLYLENE GLYCOL  
B.  
CHOOSING THE PROPER  
GLYCOL:  
NOTE: GLYCOL FREEZE POINT MUST BE 25˚F BELOW  
LOWEST SETPOINT  
1.  
For getting the most efficiency from your system, a  
propylene glycol such as “DowFrost” is a must. DowFrost  
contains special corrosion inhibitors for low system  
maintenance and better transfer capabilities than normal  
glycols. It also has a much longer fluid life up, to 20 years  
in some cases.  
2.  
SOURCES OF INHIBITED PROPYLENE GLYCOLS: for a  
complete literature package, material, safety data sheets  
and purchasing information, contact the following:  
DOW CHEMICAL 1-800-447-4369  
(Canada 1-800-363-6250)  
Dowfrost inhibited propylene glycol  
MONSANTO CHEMICAL 1-800-459-2665  
Monsanto FS inhibited propylene glycol  
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C.  
D.  
USE OF PLAIN GLYCOL:  
1. Even through they do lower the freeze point, plain glycols  
are even more corrosive than water. The corrosion rate of  
plain ethylene glycol on iron, for example, is more than 2.5  
times faster than plain water. On steel, it is 4.5 times faster.  
AUTOMOTIVE BASED ANTIFREEZE:  
1.  
SHOULD NEVER BE USED! Automotive antifreeze contains  
silicate based inhibitors, which are compatible with  
automotive components. In an industrial application, the  
silicates will leach out and form a gel-like substance on the  
heat transfer surfaces and reduce cooling efficiency of the  
system. These silicates have shown to significantly reduce  
the lifetime of pump seals.  
E.  
MAINTENANCE RESPONSIBILITY:  
1.  
A hygrometer should be used on a regular basis to  
determine the mixture strength according to freeze point.  
The freeze point temperature should be 25°F below the  
lowest required setpoint (see charts on page 35 and 37).  
Water will evaporate from the mixture, and if you continue  
to add a premixed solution, eventually you will have too  
much glycol. It is necessary to add water or glycol to  
maintain proper freeze point temperature. The device  
pictured is by far the most accurate and easy to use for  
maintaining and checking for proper glycol levels.  
Contact:  
Misco Products:  
1-800-358-1100  
Model #7084VP  
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8.5  
CHILLER CAPACITY AND DERATE CHART  
Standard chiller rating is at 50°F. For all other temperature settings,  
output tonnage is altered as follows:  
OUTPUT  
TEMPERATURE  
°F  
FULL  
AVAILABLE %  
CAPACITY  
60  
50  
45  
40  
35  
30  
25  
20  
15  
10  
5
105%  
100%  
90%  
80%  
70%  
60%  
50%  
40%  
30%  
22%  
15%  
9%  
*
*
*
*
*
0
-5  
5%  
NOTES:  
If operation of the chiller at less than 48°F is  
required, an inhibited propylene glycol  
solution is required.  
Consult factory for chiller operation below  
20°F.  
Ambient conditions affect air cooled chiller  
operation and capacity. Standard rating is at  
95°F entering air temperature. For ambient  
air conditions greater than 95°F, chiller  
derating will occur. For ambient temperatures  
of 95-105°F, select the next larger capacity  
chiller. For ambient temperatures over 105°F,  
consult factory.  
* These ranges require special options.  
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8.6  
PRESSURE-TEMPERATURE CHART FOR R-22 REFRIGERANT  
SATURATED TEMPERATURE  
FREON PRESSURE  
40°F  
45°F  
50°F  
55°F  
60°F  
65°F  
70°F  
75°F  
80°F  
85°F  
90°F  
95°F  
100°F  
68  
76  
84  
93  
100  
112  
122  
132  
144  
156  
168  
182  
196  
THESE PRESSURE/TEMPERATURE RELATIONSHIPS ARE IN AN  
AT-REST, SATURATED CONDITION. FOR EXAMPLE, IF THE UNIT HAS BEEN IN A WAREHOUSE AT 40° AND IS  
BROUGHT INTO A ROOM WHERE IT IS 80°, IT MAY TAKE A COUPLE OF HOURS FOR THE UNIT TO WARM UP AND  
THE PRESSURE TO RISE TO THE SURROUNDING AMBIENT CONDITIONS.  
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8.7  
USEFUL ENGINEERING FORMULAS  
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8.8  
PARTS LIST  
PART  
DESCRIPTION  
Caster - 3” swivel  
Caster - 3” rigid  
Coil - Chas 3100  
800000  
810000  
895010  
1527475  
2169475  
2971475  
4345900  
4714350  
6206498  
6214050  
6648300  
7550000  
7591075  
7732200  
8213775  
8828995  
Condensing unit #F3AHA101CFV-201 203-1-60 R-22  
Filter drier - C-0525  
Expansion valve - #EVGE-1-CP100  
CONTROLLER - #EWPC 902T Type J  
Pump motor - 1/2 HP 1725 RPM 230-1-60 #3K090  
Thermocouple - Type J ungrounded #SP-498J A4 B48  
Procon pump - #CB2507XH AMP #1113  
Relay - #GL7-2A-TUBJ-CB 230 volt  
Pressure switch - P70MA-1  
Rocker switch - #2600A21E  
Reservoir tank - #06299  
Transformer - #44F3095  
Bypass valve - #5300A 1/2”  
Note: this is a typical parts list. Please obtain exact model # and serial # before contacting  
our parts department to assure an exact replacement part.  
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Conair has made the largest investment in customer support in  
the plastics industry. Our service experts are available to help  
with any problem you might have installing and operating  
your equipment. Your Conair sales representative also can help  
analyze the nature of your problem, assuring that it did not  
result from misapplication or improper use.  
WERE HERE  
TO HELP  
To contact Customer Service personnel, call:  
HOW TO CONTACT  
CUSTOMER  
SERVICE  
From outside the United States, call: 814-437-6861  
You can commission Conair service personnel to provide on-  
site service by contacting the Customer Service Department.  
Standard rates include an on-site hourly rate, with a one-day  
minimum plus expenses.  
If you do have a problem, please complete the  
following checklist before calling Conair:  
BEFORE YOU  
CALL ...  
Make sure you have all model, serial and parts list  
numbers for your particular equipment. Service  
personnel will need this information to assist you.  
Make sure power is supplied to the equipment.  
Make sure that all connectors and wires within  
and between control systems and related  
components have been installed correctly.  
Check the troubleshooting guide of this manual  
for a solution.  
Thoroughly examine the instruction manual(s)  
for associated equipment, especially controls.  
Each manual may have its own troubleshooting  
guide to help you.  
Additional manuals and  
prints for your Conair  
equipment may be  
ordered through the  
Customer Service or  
Parts Departments for a  
nominal fee.  
Check that the equipment has been operated as  
described in this manual.  
Check accompanying schematic drawings for  
information on special considerations.  
IMS0002/0296  
SERVICE INFORMATION  
APPENDIX A-1  
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Conair guarantees the machinery and equipment on this order,  
for a period as defined in the quotation from date of shipment,  
against defects in material and workmanship under the normal  
use and service for which it was recommended (except for  
parts that are typically replaced after normal usage, such as  
filters, liner plates, etc.). Conair’s guarantee is limited to  
replacing, at our option, the part or parts determined by us to  
be defective after examination. The customer assumes the cost  
of transportation of the part or parts to and from the factory.  
EQUIPMENT  
GUARANTEE  
Conair warrants that this equipment will perform at or above  
the ratings stated in specific quotations covering the equip-  
ment or as detailed in engineering specifications, provided the  
equipment is applied, installed, operated and maintained in the  
recommended manner as outlined in our quotation or specifi-  
cations.  
PERFORMANCE  
WARRANTY  
Should performance not meet warranted levels, Conair at its  
discretion will exercise one of the following options:  
Inspect the equipment and perform alterations or adjust-  
ments to satisfy performance claims. (Charges for such  
inspections and corrections will be waived unless failure  
to meet warranty is due to misapplication, improper  
installation, poor maintenance practices or improper oper-  
ation.)  
Replace the original equipment with other Conair equip-  
ment that will meet original performance claims at no  
extra cost to the customer.  
Refund the invoiced cost to the customer. Credit is sub-  
ject to prior notice by the customer at which time a  
Return Goods Authorization Number (RGA) will be  
issued by Conair’s Service Department. Returned equip-  
ment must be well crated and in proper operating condi-  
tion, including all parts. Returns must be prepaid.  
Purchaser must notify Conair in writing of any claim and pro-  
vide a customer receipt and other evidence that a claim is  
being made.  
Except for the Equipment Guarantee and Performance  
Warranty stated above, Conair disclaims all other warranties  
with respect to the equipment, express or implied, arising  
by operation of law, course of dealing, usage of trade or oth-  
erwise, including but not limited to the implied warranties of  
merchantability and fitness for a particular purpose.  
WARRANTY  
LIMITATIONS  
APPENDIX A-2  
WARRANTY INFORMATION  
IMS0003/0796  
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