Chiller Service Manual, Page 1

Service Manual
Model 6000 Series Chiller

Information is reserved for trained, qualified technical personnel. It includes schematics & wiring diagrams.
Any repair or service to a unit is to be performed by a certified technician ONLY.
Attempting repairs outlined in this guide may result in voiding your warranty

UNPLUG THE UNIT BEFORE SERVICING

Table of Contents
SECTION 1.
SECTION 2.
SECTION 3.
SECTION 4.
SECTION 5.
SECTION 6.
SECTION 7.
SECTION 8.
SECTION 9.

TROUBLESHOOTING GUIDE
REPLACING MAIN CONTROL BOARD
CALIBRATION
TESTING REFRIGERATION IN 6X05
QUICK VALVE SEAT CHECK
MAIN BOARD CONTINUITY CHART
SPARE PARTS LIST
SCHEMATICS
WIRING DIAGRAMS

Chiller Service Manual, Page 2

SECTION 1. TROUBLESHOOTING GUIDE

Note: If the unit seems to function normally but fails to control or hold temperature steady,
first perform instructions as in "Conditions and Steps before Troubleshooting the Unit"
CONDITIONS AND STEPS BEFORE TROUBLESHOOTING THE UNIT
1. Connect the Inlet/Outlet connections with a 3 foot length of 1/2" diameter or greater hose.
2. Fill the reservoir with the same fluid and run the unit at the same setpoint temperature as the
application.
3. Check that the fluid or fluid mixture is :
a. Watery, not thick like maple syrup. Viscosity <25 centistokes.
b. Not freezing to the bottom of the reservoir or cooling coils and not within 5C of the freezing
point of the fluid.
4. See "Pump troubleshooting" section. If not pumping properly, perform checks in "Replacement of
pump" section.
5. Cooling Test : Follow steps in "Refrigeration servicing" in section "Determination of cooling
power".
6. If the unit works properly with the short length of tubing check the following :
a. Check that externally applied heat does not exceed the rated cooling power of the
refrigeration.
b. Cover or add insulation of both the internal reservoir and external application and tubing.
7. To Return To The Controller Default Settings:
1.
2.
3.
4.

Press and release the power ON button, then switch the circuit breaker off.
Press and hold the Set/Menu button while switching the circuit breaker on.
The controller will display "DEF" and go to the standby mode.
Your set temperature and other settings will have to be reset.

Problem
#1
Display does not light up

Corrective Action
1) Check that breaker CB1 is on. Check for proper line voltage.
2) Using schematic on page 8, check main board +5V at voltage regulator RG1.
a)
b)
c)

If no voltage, verify that the AC input voltage is present at SP9 and SP12.
If the AC voltage is normal, check the fuses and transformer for continuity. Repair
any open circuit.
If there is no AC voltage present at SP9 and SP12, trace the wires back to the
circuit breaker and check for continuity. Replace or repair the wire that is open.

3) Check main board copper traces for open circuits, use the Main Board CONTINUITY
CHART on pg. 6.
4) If problem still exists, replace the main board, then replace display board.
5) If the centigrade light is on, remove the wire from CN4 on the main circuit board, the
display should light up. Removed wires should be replaced or repaired.
#2
Flashes HI-L high limit

1) Perform a default as described in section 3.7 in the Operators Manual

2) Refer to the Operators Manual, section 3.4, to SET HI-L menu, raise HI-L limit above
fluid temp.
3) Using schematic on page 8, check sensor voltages and resistances.

Chiller Service Manual, Page 3

#3
Reads E-5F sensor failure

1) Using schematic on page 8, examine the 4 wires from the temperature probe at their
solder terminals on the main circuit board. The 2 red and 2 black wires should be
securely soldered. Solder any loose or torn wires.
2) Check sensor voltages and resistances shown on schematic.
3) Check main board, -5V at voltage regulator RG2.
4) If voltages and resistances are OK, replace main circuit board.

#4
Continuously pumps
#5
Compressor continuously
runs
#6
Readout not within
0.5C
#7
Unit is not pumping

1) Using schematic on page 9, unsolder R10. If unit still pumps, ALT2 is shorted.
2) If pins 4 and 6 on U8 is less than 50K ohms, U8 is shorted.
1) Using schematic on page 9, unsolder R14. If compressor and fan still run, ALT3 is
shorted.
2) If pins 4 and 6 on U10 is less than 40 K ohms, U10 is shorted.
1) Using schematic on page 8, check that RTD probe is within 0.19 ohms. (Subtract
resistance of probe wires and your test leads from reading.)
2) Using schematic on page 8, check R5. It should be between 199.8 and 200.2 ohms, if
not, then there is no field calibration. Replace main board.
1) The fluid in the evaporator may be frozen. The evaporator is considerably colder than
the fluid temperature. For temperatures below 15C, use a fluid mixture with a suitable
temperature range for the set point desired. Refer to the Operators Manual, section 2.2
for recommended fluid mixtures.
2) Using schematic on page 8, Check voltage across SP5 and SP6 on main board. If no
line voltage measured, replace main board.
3) Using schematic on page 8, Check voltage across SP5 and SP6 on main board. If line
voltage is measured low, verify pump motor is running. Check fluid level in entire
system to be sure the pump is receiving fluid. Check for blockage within the circulating
system.
4) The coupling key between the motor shaft and pump head is a sacrificial type designed
to prevent damage if the fluid freezes. If the coupling key is worn, replace it.

#8
Unit will not turn on/off
#9
Set temperature cant be
changed
#10
The circuit breaker trips

b) If the on/off switch does not works, the display is defective and needs to be replaced.
1) Perform a default as described in section 3.7 in the operators manual to reset the
microprocessor.
2) The rotary encoder on the display is defective. Replace the display board.
1) Using a clamp ammeter, monitor the AC current into the circuit breaker.
a)
b)

If the current is less than the amount printed on the serial tag, replace the
defective circuit breaker.
If the current is greater than the specified amperage, determine the source of the
extra current draw.

2) Take an ohmmeter reading from all the compressor terminals to ground.

a)
b)

Any resistance is an indication of a shorted compressor. Replace the

compressor.
Ohm the pump motor from ground to the motor leads. Any resistance is an
indication of leakage current internal to the motor. Replace the motor.

3) Replace the start capacitor and start relay.

#11
Unit cools too slowly or
does not reach set point.

1) Check refrigeration system for possible leaks.

2) External heat load is beyond unit's capacity.
3) Check that modulating valve is operating properly.

Chiller Service Manual, Page 4

#12
Unit does not cool at all.

1) Check that compressor & compressor fan are running. While the unit is set for cooling,
check voltage across connector CONN14 on modulating board If the voltage is not
~28Vdc, replace the modulating board.
2) If the compressor & compressor fan are not running, check the circuit breaker, power to
the compressor (line voltage), compressor overload, compressor relay, and compressor
start & run capacitors.
3) Listen for the modulating valve to "click" (open and close).
a)
b)

If valve is not clicking within 30 seconds, then replace the valve.

If the valve clicks, then stays open, the unit may be leaking and low on charge.

4) Check that set point is below fluid temperature.

5) Check the head & suction sensor temperature. If either sensor reads -51C or +201C,
the microprocessor will not open the solenoid valve. Replace the defective sensor
assembly.
6) The pump motor may not be running so the fluid will not cool
a)
c)

Verify that the pump motor is running.

Check the pump voltage as outlined under Problem unit not pumping, page 4.

Check for frozen fluid.

SECTION 2. REPLACING MAIN CONTROL BOARD

When removing/replacing the main control board, always remove/replace the bath temperature
probe included with the board. Temperature probes are checked at the factory to be within
tolerance only when used with that board.

the main control board is located by removing a side panel.

SECTION 3. CALIBRATION
These units are rated to be within 0.5C of actual temperature over the entire temperature range.
There is no calibration procedure. To check calibration you need to have a traceable thermometer
of known accuracy of 0.05C accuracy or better. Check at a least two points, one cold and one
hot. If the user temperature extremes are known, check at or near these points. The readout must
be within 0.5C over this range to pass

SECTION 4. TESTING REFRIGERATION IN 6X05

6x05 models are equipped with a modulating valve and two temperature sensors. The modulating
valve substitutes for an expansion valve to maximize refrigeration power when needed. When near
the setpoint temperature, the modulating valve also proportions refrigerant flow for very stable

Chiller Service Manual, Page 5

temperature control and to conserve energy. Refrigeration pressures and temperatures will change
considerably with use.
To observe the HEAD (HEAd) and SUCTION (SUCt) temperatures:
1)
2)
3)
4)
5)

Press and HOLD the SET/ENTER button until the display reads Unit.
Then release and press and HOLD SET/ENTER button once again until the display reads
EPC.
Then turn the set knob clockwise until it reads HEAd or SUCt.
Then press the SET/ENTER button to read the temperature.
Use the following REFRIGERATION SERVICING section for example of head and suction
temps, and pressures.

Refrigeration Parameters
Model

suction temp

head temp

suction pressure

head pressure

6205

14C - 19C

67C - 75C

40 - 55 (psi)

155 - 175 (psi)

6305

10C - 15C

65C - 85C

40 - 50 (psi)

145 - 165 (psi)

6505

10C - 15C

65C - 75C

40 - 45 (psi)

180 - 200 (psi)

6705

10C - 16C

65C - 80C

40 - 50 (psi)

175 - 200 (psi)

6105

8C - 15C

64C - 81C

31 - 45 (psi)

150 - 185 (psi)

To properly test your unit, testing conditions for 6000 series at 20C:
1)
2)
3)

Set temperature at minimum -10C or less.

Maximum heat load added to maintain water temperature below 20C.
Ambient temperature between 20 - 25C.

SECTION 5. QUICK VALVE SEAT CHECK

With a refrigeration pressure gauge attached to the suction line, an easy check can be done to
check the modulating valve and compressor valve seats for a good seal.
1)

The two black wires to the modulating valve go to CONN14. Remove this connector from the
modulating PC board.

2)

Run the refrigeration for about 30 seconds. The suction should drop below -20 psi

3) Shut off the unit. The pressure should not change for at least a minute.
If steps 2 or 3 do not correct the problem, then the compressor valves and/or modulating valve are
defective. Reconnect CONN14 when finished.

Chiller Service Manual, Page 6

SECTION 6. MAIN BOARD CONTINUITY CHART

If all power supply voltages are present and the unit does not run, check all of these board traces in
the chart below for continuity. Repair any two points by soldering a small wire across any of the
two points that do not make connection. U12 and U2 are the same IC chip.

FROM

TO

FROM

TO

FROM

TO

FROM

TO

U7,1

TP4

U7,17

U5,11

U6,9

U3,26

U7,50

U12,10

U7,1

U12,1

U7,18

U6,16

U6,11

U12,2

U7,51

U12,19

U7,2

C5,

U7,19

RN,4

U7,38

U12,23

U7,52

U12,18

U7,3

C6,

U7,19

U6,5

U7,39

U12,21

U7,53

U12,17

U7,4

U7,7

U7,20

U6,4

U7,40

U12,24

U7,54

U12,16

U7,4

U7,8

U7,21

U5,3

U7,41

U12,25

U7,55

U12,15

U7,6

U11,7

U7,22

U6,3

U7,43

U12,3

U7,56

U12,13

U7,8

RN1,1

U7,23

RN1,8

U7,44

U12,4

U7,57

U12,12

U7,9

RN1,9

U7,25

CN9,4

U7,45

U12,5

U7,58

U12,11

U7,9

U6,17

U7,26

CN9,3

U7,46

U12,6

U7,62

U12,27

U7,11

U5,1

U6,6

U7,31

U7,47

U12,7

U7,63

U12,22

U7,14

U5,4

U6,7

U3,1

U7,48

U12,8

U7,16

U5,2

U6,8

U3,27

U7,49

U12,9

SECTION 7. SPARE PARTS LIST

Description

Model 6205(P)

Model 6305(P)

Model 6505(P)

Model 6705(P)

Model 6105(P)

Display PCB

500-109

500-109

500-109

500-109

500-109

Modulating PCB,
120V
240V

500-101
500-102

500-101
500-102

500-101
500-102

500-101
500-102

500-101
500-102

Main PCB
120V/60Hz
240V/50Hz

500-144
500-145

500-144
500-145

500-144
500-145

500-144
500-145

500-144
500-145

Turbine Pump

6205T 215-308

6505T 215-308

6705T 215-305

6105T 215-305

PD Pump Head,
1 gpm
4 gpm

215-105
-----

215-105
-----

215-105
-----

----215-106

----215-106

PD Pump Motor,
120V/60Hz
240V/50Hz

215-102
215-103

215-102
215-103

215-102
215-103

215-102
215-103

215-102
215-103

Filter Assembly

300-098

300-098

300-098

300-098

300-098

Refrigeration
Head/Suction
Sensor Assembly

525-329

525-329

525-329

525-329

525-329

Pressure Regulator

750-032

750-032

750-032

750-032

750-032

Circuit Breaker

215-157

215-157

215-270

215-157

215-157

Refrigeration (drop-in),
120V/60Hz
240V/50Hz

750-157
750-158

750-153
750-154

750-155
750-156

---------

---------

6305T 215-308

Chiller Service Manual, Page 7

Compressor,
208-230V/ 60Hz, 134a
240V/ 50Hz, 134a

---------

---------

---------

750-126
750-127

750-128
750-129

Condenser Coil

-----

-----

-----

750-160

750-160

Condenser Fan Motor,

230V
240V

---------

---------

---------

215-188
215-188

215-188
215-188

Condenser
Fan Motor Blade

-----

-----

-----

215-076

215-076

Drier (Hard core)

750-075

750-075

750-075

750-075

750-075

Modulating Valve

750-093

750-093

750-093

750-133

750-133

Heat Exchanger Assy

590-106

590-106

590-106

590-108

590-108

Air Filter

400-388

400-388

400-388

400-388

400-388

Coupling Key (Pump)

775-088

775-088

775-088

775-088

775-088

Centrifugal Pump & Motor

120V, 50/60 Hz
215-181
240V, 50/60 Hz
215-182

215-181
215-182

215-181
215-182

215-181
215-182

215-181
215-182

Chiller Service Manual, Page 8

SECTION 8. SCHEMATICS

Schematic, 6000 chiller

Chiller Service Manual, Page 9

Schematic, Main Board

Chiller Service Manual, Page 10

Schematic, LED Display

10

Chiller Service Manual, Page 11

SECTION 9. WIRING DIAGRAMS

Wiring Diagram, 6205, 6205P, 6305, 6305P, 6505, 6505P - 120V, 60Hz

11

Chiller Service Manual, Page 12

Wiring Diagram, 6205, 6205P, 6305, 6305p, 6505, 6505p, 240V, 50Hz

12

Chiller Service Manual, Page 13

Wiring Diagram, 6705, 6705P, 6105, 6105p, 230V, 60Hz

13