Chiller Diagnostics & Theory Of Operation

Preface: This article contains a lot of Chiller related information about troubleshooting, replacing and acquiring parts. Be sure to use the table of contents to go to the pertinent area.

For a bulk of this article, you will see references about V1 vs V2 chiller, knowing the difference will really help.

Identifying An Alarm Status

V1 and V2 chillers will show alarms differently depending on the alarm. Both should have an audible beep. Look for an error on the Laser Control screen about Water Protection.

E# Alarm Indication

V1 Flow Alarm

E# Alarm Indication

Note how it flashes the Temperature, the 888 and then the E# alarm.

V1 Flow Alarm

The V1 chiller will announce a flow alarm without an E# Alarm. The red light indicator should be lit up (if not burnt out), Alarm Beeping noise and the Laser Machine told to stop lasering. The readout on the Chiller will likely be displaying the current coolant temperature.

 If you have an alarm, then the rest of this guide should be used to help troubleshoot and fix the alarm.

Alarm Codes and Indicators

This section will help determine what the alarm means.

V1 Chillers

V2 Chillers

V1 Chillers

The V1 chiller only shuts down the laser for a flow alarm. All other V1 Chiller controller alarms only indicate at the chiller and the operator must take proper action.

V1 Beeping Alarm Reasons (Flow only)

V1 Chiller Red Alarm Light ON Reasons

V2 Chillers

The V2 chiller has more codes and more reasons to beep and shut down the laser machine.

V2 Beeping Alarm Reasons

 

Alarm Troubleshooting Videos:

You can use these videos to help diagnose what may be the cause of a particular alarm.

E1

E2

E3

E4

E5

E6

E1

E1 Alarm indicates a High Ambient Air temperature. This could be caused by:

1. Room temperature being too high, higher that the value controlled by the F6 Parameter
   
2. Air Temperature Sensor Failure, it is reading the air temperature incorrectly
   
3. Dirty Filters
   

E2

E2 Alarm indicates a High Water temperature. This could be caused by:

1. Water temperature being too high, higher that the value controlled by the F4 Parameter
2. Water Temperature Sensor Failure, it is reading the water temperature incorrectly
3. Dirty Filters
4. Dirty Water
5. Low Water
6. High Usage
   

E3

E3 Alarm indicates a Low Water temperature. This could be caused by:

1. Water temperature being too high, higher that the value controlled by the F5 Parameter
   
2. Water Temperature Sensor Failure, it is reading the water temperature incorrectly
   
3. Dirty Filters
   
4. Dirty Water
   
5. Low Water
   
6. Super Low Ambient Temperature
   

E4

E4 Alarm indicates a Room Temperature Sensor Failure. This could be caused by:

1. Sensor has failed
   
2. Controller Input Failed

E5

E5 Alarm indicates a Water Temperature Sensor Failure. This could be caused by:

1. Sensor has failed
   
2. Controller Input Failed

E6

E6 alarm is for water flow alarm on V2 Chiller. 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.

1. Weak Pump
   
2. Clog
   
3. Low Coolant
   
4. Busted Tube - All coolant leaked or in tube
   

For Further guidance on the causes of the E6 alarm, please see the rest of this article.

 

E6 and Flow Alarms

Since the flow and E6 alarm are so common and has many causes, this section is dedicated to it. 

Here are some checks to perform to get an idea of what is likely wrong with your chiller and the cause of the E6 Alarm

Coolant Level

Flow Rate Test

Loop The Chiller

Water Flow Sensor

Coolant Level

Verify that there is adequate coolant for the pump to pump.

Water Level Gauge	Possible Causes
	Coolant was not properly Filled Leak - Check all connections at the chiller, machine, and tube Busted Tube - Water may be filling the inside of your laser tube and not returning to the chiller. Inspect your tube

Flow Rate Test

A good check to perform when getting an E6 Flow alarm is to actually see if the flow from the pump matches the documentation. To perform the test, you will need a gallon jug and a stopwatch (Smartphone app). Make sure the chiller is full, even beyond the green line so that there is a gallon of water to spare.

1. Turn the Chiller Off

2. Disconnect the Inlet Hose off the laser machine and place into an empty gallon jug

3. Prepare the stop watch. Turn the Chiller on

4. When water starts flowing into the Jug, start the timer

5. Stop the chiller and stopwatch when the jug is nearly full (1 Gallon of water in the jug)

6. Compare the stopwatch time to the values in the table below

Chiller Model	Peak Flow Rate L/Minute (gal/minute)	Fastest Time	Target Time
CW-5000	10L/min (2.65gal/min)	22.64 seconds	Under 35 Seconds
CW-5200	13L/min (3.43gal/min)	17.5 seconds	Under 30 Seconds

Loop The Chiller

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

If alarm stops, it could be due to a blockage or a weak pump. Check the areas below for blockage:

Area	Reference Image
Check the internal and external chiller hose connections on the Laser Machine.
Check at the laser Tube Inlet
Check at the Laser Tube outlet

Water Flow Sensor

If you can feel for water flow and the Flow Rate Test is a pass, then the switch could be suspect.  Please remove the cover from the chiller to check the water flow switch.

Remove the flow sensor cartridge from the housing by removing the 4 phillips head screws. Check that the sensor is clean and spins freely. If it is dirty, clean it.

For V1 Chillers Only:

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

 

Component Checks:

Below is a list of pictures and videos that show how to check a particular component.

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 that is in 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). If the capacitor is damaged, the compressor will not start. Replace the capacitor.

How To Check & Clean Hall Effect Flow Meter

How To Measure Hall Flow Switch

How to check the Alarm Output Continuity

Article to check with as well:

Chiller Alarm signal and Cable Troubleshooting guide for Water Protect Error

 

Identifying The Components (and links to parts)

Use the table below to find your replacement parts, be sure to check which chiller version you have, V1 or V2, prior to ordering.

Water Pumps

Power Supplies

Water Flow Sensor

Controller

Water Pumps

CHILLER	PUMP	IMAGE	WATTAGE	CURRENT	MAX FLOW	MAX LIFT	Where to Buy
CW5000	P2430		30	1.6A	10L/MIN	10M	V2
CW5200	P2450		50	2A	13L/MIN	12M	V1

The main difference between V1 and V2 chiller pumps are the electrical connectors. Both can work in either version but you would need to splice the wiring. Older V1 chillers also may not have quick connectors at all and will require wire splicing.

Power Supplies

CHILLER	PSU MODEL	IMAGE	VOLTAGE	CURRENT	SOURCE
S&A G SERIES	GM42-240160-D		24	1.6A	LINK
S&A H SERIES	GM48-240200-D		24	2A
S&A I SERIES	GM120-2400500-D		24	5A

Water Flow Sensor

Water Flow Sensor

CHILLER	SENSOR	IMAGE	VOLTAGE	TYPE	SOURCE
V1 All	HL-30		24	HALL EFFECT	LINK
V2 All	HL-30		24	Hall EFFECT

Controller

CHILLER	CONTROLLER	IMAGE	DEFAULT SETTING	SOURCE
V2 All	T-503D		INTELLIGENT	Link

 

Checking, Cleaning, & Replacing Components

Remove all power prior to performing repairs on the chiller.

Below is a list of videos on how to clean or replace certain components on your chiller. Depending on your vintage of chiller, there may be slight differences in the components.

How to remove the cover and water pump

How to Clean the water Pump

How to Replace the water Pump

How to Replace the Power Supply

How to install Water Temperature Probe

How to replace the Power 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)

 

Additional Resources

Here are some additional resources for the 5000 series chiller

• CW-5000AG Wiring Diagram
• S&W CW-5000 Series Chiller User Manual
• S&W CW-5000 Series Chiller Maintenance Manual
  
• CW-5xxx Series Chiller Alarm Connections
• Preventative Maintenance Checklist
  
• CW-5000 Series v1 and v2 Chiller Differences

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