Symptom
Possible Cause
Solution
Alarm is active on Haas Control. The flow alarm indicator on the front of the spindle chiller is on. (Red LED is on)
There is something blocking the circulation of chiller fluid. There is something blocking the chiller fluid from returning to the spindle chiller.
Make sure that there are no leaks coming from the fittings on the back of the spindle chiller. Check underneath the spindle head cover sheet metal and verify that there is no leaks coming from the fittings on the spindle head casting for the spindle chiller.
There is a low amount of chiller fluid in the spindle chiller tank.
Make sure that there is no leaks coming from the chiller unit, or from the fluid lines that deliver chiller fluid to the spindle. After fixing any leaks that caused the chiller fluid level to drop, fill the tank with a mixture of 30% Dowfrost and 70% deionized water. Refer to the maintenance section on the DC-Series spindle chiller for more information on how to fill the tank.
The pump is not working properly.
Replace the spindle chiller pump.
The flow sensor is faulty and not functioning.
Check to make sure that there is circulation in the spindle chiller fluid lines. If there is flow in the lines, you can hold the fluid lines and feel the vibrations caused by the fluid flow. If you can detect flow, but the alarm indicator is on, replace the flow sensor.
Alarm is active on Haas Control, but the normal flow indicator on the front of the spindle chiller is on. (Green LED is on)
The alarm signal cable could be damaged or not functioning.
Inspect the spindle chiller alarm cable. Check for damage on both connectors and for damage along the length of the cable. If no damage can be seen on the cable remove the alarm cable from the spindle chiller unit. Use a voltmeter to check for continuity between pins H1 and H3 of the alarm connector. If there is continuity, then there are no alarms coming from the spindle chiller unit. See procedure below for where to check continuity.
The flow alarm indicator (Red LED) is slowly lighting up and the spindle chiller display is briefly flashes. Both then turn off and this cycle repeats.
The IO PCB is leaking voltage to the spindle chiller even when the spindle chiller is not being powered on.
This is expected behavior for the DC-Series spindle chiller. The spindle chiller will function properly when commanded to turn on. See the section below DC Spindle Chiller Behavior
Spindle chiller display shows E1 message
The ambient temperature is above the maximum ambient temperature parameter.
The maximum ambient temperature parameter is set to 45 degrees Celsius in the factory. This is parameter F6. See the operation page of this chapter to see factory set parameter values. If the ambient temperature is above 45 degrees Celsius (113 Fahrenheit), see the operation page about adjusting parameter values. If the ambient temperature is below 45 Celsius, check the parameter value and replace the ambient temperature sensor.
Spindle chiller display shows E2 message
The fluid temperature is above the maximum fluid temperature parameter.
The maximum chiller fluid temperature is set by parameter F5 and is set to 15 degrees Celsius in the factory. Clean the air intake filters to allow for proper ventilation. Make sure that the chiller fluid mixture has the right proportions. The chiller fluid should be 30% Dowfrost 70% deionized water. See the maintenance section for draining the chiller fluid. See the operation page for setting parameter values if needed.
Spindle chiller display shows E3 message
The chiller fluid temperature is below the minimum fluid temperature parameter.
The minimum chiller fluid temperature is set by parameter F4 and is set to 20 degrees Celsius in the factory. Make sure that the chiller fluid mixture has the right proportions. The chiller fluid should be 30% Dowfrost 70% deionized water. See the maintenance section for draining the chiller fluid. See the operation page for setting parameter values if needed.
Spindle chiller display shows E4 message
The ambient temperature sensor is failing.
Replace the ambient temperature sensor.
In industrial machining processes, such as milling or drilling, oil is mainly used as a cooling lubricant (KSS). In this process, the oil not only lubricates the application and thus reduces friction, but it also dissipates heat from the process in question. Use of oil prevents heat-related quality losses on the workpiece or even damage to the tool and the machine.
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To this end, a cooler must deliver the chilled oil evenly and at the appropriate temperature to the application. This requires reliable pumps that provide the oil at the right pressure and precise control of the cooling temperature. In addition, because oil often has residual contamination despite filtration, an oil cooler should be able to handle slightly contaminated cooling media and be easy to clean.
Two chiller types for oil cooling
HYFRA Alpha series continuous flow chillers cool oil as it flows through the cooler. With a small footprint, they operate with capacities from 5 kW to 80 kW (1.5 tons to 22.5 tons). Up to 28 kW (7.5 tons), the space requirement is only 0.5 m², and up to 80 kW (22.5 tons), 1 m². Thus, the units fit well into various machine layouts, where they can also be placed at a generous distance from the application. The powerful pumps of the continuous flow chillers transport the oil reliably and evenly while monitoring the flow rate.
The HYFRA Gamma series of immersion chillers are inserted directly into the oil tank for cooling. Their cooling capacity ranges from 5 kW to 160 kW (1.5 tons to 45 tons). The smaller units with cooling capacities up to 28 kW (7.5 tons) also manage with a footprint of only 0.5 m². The robust agitator of the “drop-in” chillers ensures a uniform temperature by mixing the oil in the tank. For cleaning, the units can be easily removed from the cooling medium by means of crane lift eyes.
More efficiency through innovative functions
In addition to their reliability and compactness, HYFRA's oil chillers are also characterized by their efficient operation. For example, the microchannel evaporator with its special design results in improved heat exchange. Chillers with this evaporator therefore require up to 70% less refrigerant.
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Units with FleXX technology control the operation of components such as the expansion valve or fan according to demand. This flexible form of cooling saves up to 30 % energy and also reduces refrigerant requirements. In addition, the FleXX models allow the temperature to be controlled particularly precisely with an accuracy of up to 0.1 K.
Chiller selection and set-up is based on an intensive exchange between the customer and HYFRA. In this way, the devices are precisely matched to the requirements of the customer's application. Should the requirements for a cooler change fundamentally at a later date, HYFRA quickly adapts the unit to the new conditions with modification kits.
On request, HYFRA can also develop a completely customized cooling solution that provides suitable cooling even under particularly challenging environmental conditions. For these individual projects, HYFRA provides all services from a single source - from the concept to the ready-to-operate cooling system. This reduces the coordination effort and at the same time accelerates the project process.
Our HYFRA liquid chillers or our HYFRA coolant chillers might be interesting for you as well.
All immersion chillers from HYFRA consist of a hood section in the upper area and an immersion section in the lower half. Only the immersion part with the evaporator is inserted into the oil. Depending on the model, the oil chillers have an immersion depth of 50 cm to 66 cm (20 inches to 26 inches) for powers from 5 kW to 80 kW (1.5 tons to 22.5 tons). For proper cooling, the liquid must have a minimum level. The level depends on the size of the cooler.
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