Chiller Diagnostics & Theory Of Operation

Chiller Diagnostics & Theory Of Operation



Identifying An Alarm Status


If the chiller control panel is showing normal but you have an alarm status (red light, audible buzzer, and the alarm output which indicates water protect warning on the laser control panel) it can be a few things. We will explore the basic operation of the chiller's electrical systems and some things to check, as well as information on maintaining and repairing the unit.


System Overview & Precursory Power Checks

Video Overview

Here is a video explaining the systems of the chiller and some thinks to look for when troubleshooting your 5000 series chiller



Wiring Diagram

Here is the wiring diagram for the 5000 series chiller


Additional Resources

Here are some additional resources for the 5000 series chiller


You can find all of our chiller documentation HERE.

Diagnostic Procedures

Here are the steps to take when troubleshooting the chiller. 

Please note, we will need the chiller serial number so you may want to go ahead and snap a pic: 




Checking the coolant level

ALWAYS CHECK THE COOLANT LEVEL FIRST! Verifying that there is enough clean distilled water in the system is critical. The Preventative Maintenance Checklist advises that you drain the system and refill with fresh distilled water every month.



Checking for proper circulation

Please connect a water hose between water inlet and outlet on chiller to check the water circulation, like below: 




Does alarm stop？


If alarm stops, so maybe the water hose in the laser machine was blocked somewhere, please check like below:







If alarm continues, check if the water circulation is normal from the water hose between water inlet and outlet on chiller (Abnormal condition—intermittent water circulation or without water circulation). 





Changing The Water


Change the  water (distilled only) and clean the filters on the sides of the chiller. The filters allow for air flow to help the heat exchanger work at optimum performance. If you are in a dusty environment, you may need to clean them more frequently. The water is changed to prevent Algae buildup. You should target changing your water every 3-4 months. If you do develop an algae build up, you will need to perform a system flush. 


You will need about 1.5 gallons of distilled water every time you change your water. The chiller does not consume water, so you should also empty out the same amount of water.

If water drains slowly from drainage nozzle during water changing, please remove the silver fill cap.



Troubleshooting E1 Alarm



Troubleshooting E2 Alarm

Troubleshooting E3 Alarm


Troubleshooting E4 Alarm



Troubleshooting E6 Alarm

E6 alarm stands for water flow alarm. When the alarm is triggered, the alarm code and the water temperature will be displayed alternatively  with beeping. In this case, users can stop the beeping by pushing any button, but the alarm code can’t be removed until the alarm conditions are eliminated.


There are many causes for the water flow alarm. It could be the clogging inside the internal/external waterway. It could be that there are impurities inside the water pump. Or it might be wearing out of the pump rotor or wearing out of the pump itself. After the real cause is located, the alarm can be removed. 


Water Flow Sensor Failure

Water circulation is normal, but chiller still alarms.
Please open the cover of the chiller to check the water flow switch.



Cut off the four wires, then connect red and red wire, connect black and yellow wire without water flow switch, then check if the alarm will stop after restart the chiller.


If the alarm stops, the switch is broken and needs replacement.

How To Check The Compressor For Operation


Touch the position shown in the picture with his hand, and see if there is regular vibration after the water chiller is powered on.





How To Check The Capacitor

According to the instructions in the video, use a multimeter capacitance mode to measure whether the capacitor of the water chiller is damaged. (If the measured value shows 0μF, it means the capacitor is damaged).






How To Check & Clean Hall Effect Flow Meter



How To Measure Hall Flow Switch



Alarm Output Continuity Check


Identifying The Components (and links to parts)

Water Pumps

CHILLERPUMPIMAGEWATTAGECURRENTMAX FLOWMAX LIFTSOURCE
S&A G SERIESP2430301.6A10L/MIN10MLINK
S&A H SERIESP2450502A13L/MIN12MLINK
S&A I SERIESP24100N/A1005A16L/MIN25MLINK


24V Power Supplies

CHILLERPSU MODELIMAGEVOLTAGECURRENTSOURCE
S&A G SERIESGM42-240160-D241.6A
S&A H SERIESGM48-240200-D242A
S&A I SERIESGM120-2400500-D245A


Water Flow Sensor

CHILLERSENSORIMAGEVOLTAGETYPESOURCE
S&A G, H, AND I SERIESHL-3024HALL EFFECTLINK




Temp Controller

CHILLERCONTROLLERIMAGEDEFAULT SETTINGSOURCE
CW 5000 SERIEST-503INTELLIGENTLINK
N/AT-504CONSTANT SETPOINTN/A
CWFL SERIEST-506N/AN/A


Checking, Cleaning, & Replacing Components

How To Remove The Cover And Pump

REMOVE ALL POWER TO THE CHILLER BEFORE ATTEMPTING REPAIRS




How To Clean The Water Pump




How To Replace The Water Pump




How To Replace The 24v Power Supply




Temp Probe Installation



How To Replace Chiller AC Power/Fuse Socket

be sure to get the fuse from the current socket just in case the new one doesn't have a fuse in it. there is also usually a spare fuse in the toolbox, just in case



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