Sterling Saw A0544325 User's Manual
Contents
1. 2 N 1L1 G 171 1MTR Compressor 1L2 E 1T2 1L2 1L1 211 2MTR Fan Earth Remote 212 ground interlock by others 230V Control power ON OFF Jumper URGE EE 1T Subpanel 1S 1LT 1FU l 2 ground 1 x1 I 115V 2 1S U G 15T Power On Plc zc aris Vana E EE I n Low Refri High Refri 3 No Flow i Pres 4 Pres S 3 y R 2LT i R 3LT R 4LT VA amp 248 mn D se Nae cet E 1FLS 1PS 2PS Condensing unit 4 5 5 6 7 1 1 contactor I enr a 1 i l G SET 1 e Compressor On nt 2 Legend 6 7 8 9 10 Customer wiring Customer supplied components Jumper ACNTL Optional components YEL RED Type K thermocouple D smc Series Chillers Page 31 Notes Page 32 ID smc series Chillers 8 Troubleshooting Guide Problem Possible cause Solution Check main disconnect No power fuses wiring and power lead to the unit Voltage must be within plus Wrong voltage supplied to or minus 10 of the Chiller will not run the chiller nameplate rating Defective on off switch Control circuit fuse blown Replace check the transformer Defective control transformer Li Ere acad Make sure that the coolant solution is right for the Improper water glycol process must be 7596 soluti2. Microprocessor Control e 25 5 1 Introduction 5 2 Setting the Process Water Temperature 5 3 Setting the Alarm Value Optional Graphic Panel 27 6 1 Indicator Lights 6 2 Switches Routine Maintenance eese eene nnn nnn nnn 29 7 1 Lubrication 7 2 Condenser Maintenance Troubleshooting Guide 33 mm SMC Series Chillers Page 5 Charts and Figures 1 SMCO050A Process Pump Curves 10 2 SMC100A Process Pump Curves 10 3 SMC150A Process Pump Curves 11 4 SMC Series Chiller Specifications 12 5 Ethylene Glycol Curve 15 6 Overhead Piping 16 7 SMC Component Identification 19 6 Piping Schematic 1 Pump with Reservoir 20 9 Piping Schematic 1 Pump without Reservoir 21 1 0 Piping Schematic No Pump No Reservoir 22 1 1 SMC Water Circuit Pressure Drop Table 24 12 SMC Control 26 1 3 Optional Graphic Panel 28 14 Typical SMC Subpanel 29 1 5 Typical SMC Wiring Schematic 30 1 6 SMC Wiring Schematic for Chillers with No Pump or Reservoir 31 1 7 SMC Spare Parts List 35 Page 6 D smc Series Chillers 1 General Information 1 1 Introduction SMC Series Water Chillers are reliable accurate and easy to use air cooled chillers designed for use with water glycol Standard range of operation is 30 F 1 C to 65 F 18 C A crankcase pressure regulating valve option is available for processes requiring a leaving water temperature of up to 75
3. D SMC 050 to SMC 150 Series 0 5 to 1 5 hp Portable Chillers Operation and Installation Manual Sterling Inc Sterlco P O Box 245018 5200 West Clinton Avenue Milwaukee WI 53224 9518 Tel 414 354 0970 Fax 414 354 6421 Part No A0544325 Bulletin No SC2 615 1 Sterling Sterlco is committed to a continuing program of product improvement Specifications appearance and dimensions described in this manual are subject to change without notice Copyright Sterling Sterlco and Sterling Inc 2003 All rights reserved Effective 7 30 2003 Part No A0544325 Bulletin No SC2 615 1 Page 2 ip SMC Series Chillers Safety Considerations SMC Series Chillers are designed to provide safe and reliable operation when installed and operated within design specifications following national and local safety codes To avoid possible personnel injury or equipment damage when installing operating or maintaining this equipment use good judgment and follow these safe practices NN NANARA R ARA A Follow all SAFETY CODES Wear SAFETY GLASSES and WORK GLOVES Use care when LOADING UNLOADING RIGGING or MOVING this equipment Operate this equipment within design specifications OPEN TAG and LOCK ALL DISCONNECTS before working on equipment It is a good idea to remove the fuses and carry them with you Make sure the chiller is properly GROUNDED before switching power on When welding or brazing in or around this equipmen
4. D smc Series Chillers Page 15 2 5 Overhead Process Considerations If your application has chilled water or process piping above the reservoir fill and vent level install a standpipe to a point 1 30 cm above the highest point in the system In applications where the process or its piping is 15 feet 4 6 m or more above the reservoir you must take steps to prevent over pressurization of the reservoir This condition can occur on system shutdown when the water in the system drains into the reservoir To prevent this install a check valve in the unit TO PROCESS line and a vacuum breaker at the high point of the return FROM PROCESS line See Figure 6 on Page 18 for more information Note The reserve capacity of the reservoir can hold a volume equal to 20 feet 6 1 m of 1 inch 2 5 cm pipe Figure 6 Overhead Piping The reservoir vent amp fill line Vent Vacuum Breaker to be piped 12 above the highest Assembly point of the system The vent line must remain open to the atmosphere Process Return Strainer Process Supply E il Add check valve if system piping extends 15 feet above reservoir Indicates end of STERLCO piping Page 16 ED smc Series Chillers Sequence of Operation Important The SMC unit has a leaving water temperature range of 30 F 1 C to 65 F 18 C Do not attempt to run the SMC unit outside this temperature range or damage to the unit may occur When operating the SMC un
5. Do not extrapolate pump curves Page 10 D smc Series Chillers Figure 3 SMC150A Process Pump Curves SMC150A PROCESS PUMPS SELECTIONS TOTAL HEAD IMTRS PSI FEET 60 HERTZ PUMP CURVE 160 U S GALLONS PER MINUTE LITRES T T U T T T T T PER MINUTE 7 6 E 10 6 12 1 13 6 15 1 16 7 18 2 19 7 21 2 22 7 2 0 z 2 8 3 2 3 6 4 0 4 4 4 8 5 2 5 6 6 0 T CURVES REPRESENT PUMP DISCHARGE ADJUSTED FOR INTERNAL BY PASS Do not extrapolate pump curves D smc Series Chillers Page 11 Figure 4 SMC Series Chiller Specifications Optional gauge package Optional gauge package Power cable entrance either side Side cover handig Sight glass j Drain plug Des 3 4 NPT No Flow indicator To Process for pumpless 3 4 NPT units only 1a me in 6 From Process 3 4 NPT H Th 20 26 Optional Casters Rear View Front View Right Side View Capacity 65 F Ambient Model Number Btuh SMC 050 8 100 4 800 SMC 100 14 000 9 550 SMC 150 25 400 16 000 1 Capacity 10 C Capacity 50 F Ambient Nominal Chilled Compressor Capacity 18 C LWT 24 C LWT 32 C Chilled Nominal Water Ipm Ambient Ambient watts watts SMC 050 2 374 1 407 SMC 100 4 103 2 800 SMC 150 7 444 4 690 Compressor watts P
6. mm SMC Series Chillers Page 17 3 3 High Pressure Cutout The high pressure cutout is an electro mechanical safety feature that opens the control circuit if the system condensing pressure exceeds a safe level The chiller will automatically restart when the pressure drops back to an acceptable level Model Cuts out if condensing pressure exceeds SMCO50A 275 psi 1 897 kPa SMC100A 275 psi 1 897 kPa SMC150A 400 psi 2 759 kPa Important Call a refrigeration service technician to analyze the problem if high pressure recurs 3 4 Low Pressure Cutout The low pressure cutout is an electro mechanical safety feature that prevents compressor suction pressure from dropping below a preset point It is factory set to open the control circuit when pressure drops below a safe level The chiller will automatically restart when the suction pressure reaches an acceptable level Model Cuts out if suction pressure falls below SMCO50 15 psi 103 kPa A A SMC100 15 psi 103 kPa SMC150 35 psi 241 kPa A 3 5 Remote Start Stop Interlock A contact is provided to allow interlocking of the SMC Series Chiller with process controls To use this feature remove the jumper between Terminals X1 and 1 on Terminal Block 1 Supply a switch or dry contact interlock connected in series between these two terminals See Figures 14 and 15 on Pages 32 and 33 for more information Page 18 D smc Series Chillers Figure 7 SMC Componen
7. must be balanced on the forks M Lift slowly and only high enough to clear the skid Use a pry bar if necessary to remove the skid from the unit M Lower slowly The unit will land on its feet or casters and can be moved into position Page 8 nm SMC Series Chillers 1 6 In the Event of Shipping Damages Important According to the contract terms and conditions of the Carrier the responsibility of the Shipper ends at the time and place of shipment The Carrier then assumes full responsibility of the shipment M Notify the transportation company s local agent M Hold the damaged goods and packing material for the examining agent s inspection Do not return any goods to Sterlco before the transportation company inspection and authorization M File a claim against the transportation company Substantiate the claim by referring to the agent s report A certified copy of our invoice is available upon request The original Bill of Lading is attached to our original invoice If the shipment was prepaid write us for a receipted transportation bill M Advise Sterlco regarding your wish for replacement 1 7 If the Shipment is Not Complete Check the packing list The apparent shortage may be intentional Back ordered items are noted on the packing list You should have M SMC Series Chiller M Bill of Lading M Packing List M Operating and Installation Packet Re inspect the container and packing material to see if smaller item
8. 537908 A0537915 A0543063 A0537916 A0537917 A0501642 A0104093 A0537974 Units with the optional SMC graphic panel D smc Series Chillers Page 35 Service Notes Page 36 D smc Series Chillers Service Notes D smc Series Chillers Page 37 Parts Department Call toll free 7am 6pm CST 800 783 7835 or call 414 354 0970 The Sterling Sterlco Parts Department at Sterling Inc is ready to provide the parts to keep your systems up and running Sterling Sterlco replacement parts ensure operation at design specifications Please have the model and serial number of your equipment when you call Consult the Customer Parts List included in your information packet for replacement part numbers Service Department Call toll free 8am 5pm CST 800 783 7835 or call 414 354 0970 Emergencies after 5pm CST call B47 439 5655 Sterling Sterlco has a qualified service department ready to help Service contracts are available for most Sterling Sterlco products Sales Department Call 414 354 0970Monday Friday 8am 5pm CST Sterling Sterlco products are sold by a world wide network of independent sales representatives Contact our Sales Department for the name of the sales representative nearest you Sterling Sterlco Ste rl N 5200 West Clinton Avenue Milwaukee WI 53224 9518 414 354 0970 e Fax 414 354 6421 Page 38 D smc Series Chillers
9. F 24 C SMC models are available in hp 373 W 1 hp 746 W and 1 hp 1 118 W models and have an internal six gallon 23 liter reservoir All models are self contained fully assembled and shipped ready to use A properly installed operated and maintained SMC Series Chiller will provide many years of reliable operation To get the most satisfaction from your new chiller read and follow the instructions in this manual 1 2 Necessary Documents The following documents are necessary for the operation installation and maintenance SMC Series Chillers Additional copies are available from Sterlco Familiarize the appropriate personnel with these documents M This manual M The electrical schematic and connection diagram mounted inside the control enclosure Typical schematics for general reference are provided in Figures 14 and 15 on Pages 32 and 33 M The operation and installation manuals for installed accessories and options M The Customer Parts List included in the information packet 1 3 Models Covered This manual provides operation installation and maintenance instructions for SMC Series Chillers Model numbers are on the serial tag Please know the model number serial number and operating voltage of your chiller if you need to contact Sterlco SMC Series Chiller models are designated by approximate compressor horsepower A SMC050 chiller has a hp 373 W compressor a SMC100 chiller has a 1 hp 746 W compresso
10. age 12 Amp Draw 230 1 60 Dimensions nes Process Connection 1 3 hp 24 psig 1 3 hp 2 4 gpm 34 psig 1 3 hp 3 6 gpm 24 psig Process Connection 224 watts 4 5 Ipm 207 kPa 224 watts 9 0 Ipm 234 kPa 224 watts 13 6 Ipm 207 kPa Operating Shipping D smc Series Chillers 2 Chiller Installation 2 1 Electrical Connections Check serial tag voltage and amperage requirements and make sure your electrical service conforms See Figure 4 on Page 12 for total running amps Bring properly sized power leads and ground from a fused disconnect installed by your electrician to the main power terminal in the chiller s electrical enclosure M Electrical connections must comply with all applicable electrical codes M The chiller must be grounded in accordance with NEC Article 250 M Voltage must be within 10 of the chiller s nameplate rating 2 2 Process Water Connections M All external chilled water connections to the process must be of adequate size M See Figure 6 on Page 18 for sizing recommendations M The largest possible openings and passages should be provided for the flow of chilled water through platens dies molds or other pieces of equipment Important Keep any pressure drop in external process piping to an absolute minimum for optimum unit operation To Process Connect the TO PROCESS chilled water supply outlet to the process being cooled From Process Connect t
11. e chiller The SMC chiller should continue to run until the switch is turned OFF Put the SMC chiller under a process load Set the microprocessor control to the desired process temperature setpoint using the EA and buttons See Chapter 5 on Page 27 for more information Check the pump amp draw and pump pressure The amp draw reading must be within the running load and service factor amps Operate the chiller looking for leaks and listening for unusual noises or vibrations that could indicate improper operation mm SMC Series Chillers Page 23 Figure 11 SMC Water Circuit Pressure Drop Table Mod Gallons per minute AP psig SMC050A 24 0 SMC100A SMC150A Page 24 D smc Series Chillers 5 Microprocessor Control 5 1 Introduction Standard SMC Series chillers use a microprocessor based controller The controller is a modular self contained unit that can slide from its mounting housing It is factory set and adjusted no field adjustment to the internal controls is necessary 5 2 Setting the Process Water Temperature e Press E until the SP indicator lights e Press Or to raise or lower the setpoint to the desired leaving water temperature Note SMC leaving water temperature range of operation is 30 F 1 C to 65 F 18 C e Press c to display the current process temperature SP and AL are off 5 3 Setting the Alarm Value e Press E until AL lights e Press Or to raise or lower the ala
12. he FROM PROCESS chilled water return inlet to the return from the process back into the chiller for cooling and recirculation M Sterlco recommends a strainer on the FROM PROCESS return line mm SMC Series Chillers Page 13 Process Water Bypass All SMC chillers have an internal bypass device patent pending If the process flow becomes blocked during chiller operation this component allows water to flow through the chiller This protects the chiller from freeze up excessive pressures and pump damage and allows other safety features to remain effective 2 3 SMC Condenser Air Supply SMC chillers use the surrounding air to cool the condenser M Condenser air entering the SMC unit should be at least 65 F 18 C Operation with air below 65 F 18 C can cause the low pressure cutout to shut down the chiller due to the low refrigerant pressure Install the chiller in an area where there is free passage of air for condensing Provide 18 46 cm or more clearance for the chiller s air intake Make provisions to exhaust the heated air discharged from the chiller Do not put the SMC unit where steam hot air or fume exhausts will be drawn into the condenser E SRN S Air cooled condensers must be cleaned frequently Neglect reduces capacity increases operating costs and leads to possible chiller failure See Chapter 7 on Page 31 for cleaning instructions M Normal condensing pressure with 95 F 35 C air is approximatel
13. it between 30 F 1 C and 40 F 5 C you must use a solution of 75 water and 25 industrial grade ethylene glycol with a suitable corrosion inhibitor to protect the SMC unit from freeze up See Figure 5 on Page 17 for more information Such damage is not covered by the Sterlco warranty 3 1 Chilled Water Circuit Fig M KR NIE ures 8 9 and 10 Process cooling water supply and return connections are made at the pipe stubs at the rear of the chiller Warm water returns from the process and enters the reservoir tank The process water is pumped through the evaporator where it is cooled The coolant flows to the process and returns to repeat the cycle A chilled water bypass assembly patent pending between the supply and return lines guarantees a constant flow through the evaporator during intermittent low or no flow conditions A flow switch in units without pumps will prevent the compressor from running without adequate flow through the evaporator 3 2 Refrigeration Circuit Liquid refrigerant from the condenser passes through a filter dryer which removes moisture and other contaminants The refrigerant then passes through the thermal expansion valve which allows the refrigerant to expand and cool the inside of the heat exchanger The refrigerant flows through the suction line to the compressor The refrigerant gives up its heat as it re condenses to a liquid in the condenser and the cycle starts over again
14. m capacity Brush or vacuum light dirt accumulations Avoid bending or damaging the fins Heavy soil accumulations on the coil require professional steam cleaning washing from the outside only makes matters worse Figure 14 Typical SMC Subpanel Distribution Grounding Lug Terminal Blocks Control Voltage Transformer Pump Condenser Contactor Contactor mm SMC Series Chillers Page 29 Figure 15 Typical SMC Wiring Schematic 2 111 de 171 7 1MTR Pump 1L2 172 4 1L1 RE 271 2MTR Compressor gt i 1L2 x 2T2 Earth si ground 3MTR Fan 3T2 Remote interlock 1L2 1L1 by others Control 230V power ON OFF 1T J Subpanel 1S 1LT RE 1FU ground o 1 X1 I 115V 2 t rx G ISET Power On Pump 3 starter S E ES r A ER E E i Low Refrig Hi Refrig 1 Pres Pres Pump On R 3LT R ALT e T TT ov oRisFljEx EI F 1PS 2PS Condensing unit 4 5 6 t 2c contactor eee ee TRS 1 XSLT l G Compressor On 6 TA 8 10 1CNTL Jumper Legend 1 2 3 5 Customer wiring Customer supplied components Optional components Q YEL RED Type K Thermocouple Page 30 D smc series Chillers Figure 16 SMC Wiring Schematic for Chillers with No Pump or Reservoir 1C
15. on water and 25 glycol See Figure 5 on Page 17 for more information pump curves Check for partially closed Pump pressure is too high Restricted water flow valves etc Be sure all lines are properly sized The leaving water temperature is too high D smc Series Chillers Page 33 L Problem Possible cause Solution Refrigerant is low Check the refrigerant charge Sight glass should be clear Pressure switch contacts are while compressor runs Call open for service if bubbling or foaming Refrigerant high pressure Check for dirty condenser cutout switch contacts are Check for condenser air Pump runs compressor will open obstruction not Defective fan motor Repair or replace Check for high low voltage Compressor internal overload Must be within plus or minus is open Allow time to cool 1096 of the nameplate rating and reset Check for poor compressor electrical connections Broken wire in the TUN Locate and repair compressor control circuit Restricted condenser airflow Clean the condenser Unit low on refrigerant Call Service Unit runs continuously but m Inefficient compressor Call Service not enough cooling power Unit undersized for Call Sales Representative application Page 34 D smc Series Chillers Figure 17 SMC Spare Parts List Part number A0537868 A0537899 A0534584 A0534586 A0500857 A0534269 A0537955 A0533873 A0539409 A0103778 A0537900 A0
16. r and a SMC150 chiller has a 1 hp 1 118 W compressor mm SMC Series Chillers Page 7 1 4 Available Options SMC Series Chillers are available with options that tailor the unit to your requirements Some are factory installed some can be retrofitted in the field Consult your local Sterlco Sales Representative Some of these options are Special Pumps Special pump options are available for greater pressure and flow rates Bronze and stainless steel wetted surface standard flow pumps ranging from 30 psi 207 kPa to 60 psi 414 kPa are available Reservoirs SMC Series Chillers are available without a reservoir for processes that use their own reservoir Power Cord A 10 foot 3 meter power cord is available to speed SMC installation Casters Four 2 inch 5 cm swivel casters add mobility to the SMC unit CPR Valve A crankcase pressure regulating CPR valve is available for leaving water temperatures up to 75 F 24 C 1 5 Uncrating Your New Chiller SMC Series Chillers are shipped mounted on a skid enclosed in a plastic wrapper and open crated on all four sides and top M Pry the crating away from the skid and remove Use a pry bar to remove the blocks securing the unit to the skid M Lift the unit off the skid with a fork truck Insert forks between skid and chiller from the side until they protrude beyond the opposite side of the unit The forks must be equidistant from the center line of the unit and the unit
17. rm value The factory setting is 10 and should be correct for most processes Setting the alarm value to 10 creates an alarm if the process temperature rises or falls 10 F C or more from the chiller process setpoint e Press c to display the current process temperature SP and AL are off D smc Series Chillers Page 25 Figure 12 SMC Control Lights when the display shows the alarm value Lights if Process Temperature is above the set point Compressor On indicator ln L Process temperature is 10 or more above the set point ad UR Pod miri Lights when Process Temp is within 1 of the full scale Increases the process set point or alarm value S Lights if Process Temperature is below the set point f Lowers the process set point or alarm value S Lights when the display shows the process set point Scroll Steps Through Process set point actual temperature and alarm value displays Page 26 D smc Series Chillers 6 Optional Graphic Panel 6 1 Indicator Lights C PUMP ON green This indicator is lit when the pump runs COMPRESSOR ON green This indicator is lit when the compressor operates mi G 1 HIGH REFRIGERANT PRESSURE red This indicator lights if the condensing pressure exceeds a safe level The chiller goes to Idle mode until the high refrigerant pressure cutout resets The light then goe
18. s Chillers Figure 9 Piping Schematic 1 Pump without Reservoir Air cooled condenser Discharge line S j Liquid line a Refrigeration evacuation valve Relief valve Refrigeration evacuation valve Filter i Suction Filter drier Legend line E Expansion Sight Refrigeration lines Evaporator valve glass Chilled water piping Y n Condenser water piping Equalizing line End of unit piping Power element Refrigeration access valve i Temperature Optional probe pressure High TC 4 gauge pressure S P To control Ld Process pressure control Optional CPR valve Bypass Compressor Refrigeration access valve compressor mounted From Process Pump D smc Series Chillers Page 21 Figure 10 Piping Schematic No Pump No Reservoir Air cooled condenser Discharge line _ i cU 2 C K Liquid line eg Refrigeration evacuation valve Relief valve Refrigeration evacuation valve r Suction Filter Filter 1 M D drier line m Expansion Sight Legend Evaporator valve glass Refrigeration lines Y Chilled water piping Equalizing line Condenser water piping End of unit piping Power element Refrigeration access valve Temperature Optional Probe pressure High i TC 4 gauge pressure Ss P To control Low C Process o press
19. s have been missed during unpacking Determine that the item was not taken from the area before the shipment was checked in Notify Sterlco immediately of the shortage 1 8 If the Shipment is Incorrect M If the shipment is not what you ordered contact Sterlco immediately Include the order number and item M Hold the items until shipping instructions are received mm SMC Series Chillers Page 9 1 9 Returns Important Do not return any damaged or incorrect items until ou receive shipping instructions from STERLCO Figure 1 SMCO050A Process Pump Curves SMC050A PROCESS PUMPS SELECTIONS TRS PSI FEET 60 HERTZ PUMP CURVE 69 160 52 35 18 U S GALLONS PER MINUTE i 1 2 1 6 2 0 2 4 2 8 LITRES PER MINUTE 45 61 7 6 9 1 10 6 124 CURVES REPRESENT PUMP DISCHARGE ADJUSTED FOR INTERNAL BY PASS Do not extrapolate pump curves Figure 2 SMC100A Process Pump Curves SMC100A PROCESS PUMPS SELECTIONS TRS PSI FEET 60 HERTZ PUMP CURVE 160 U S GALLONS PER MINUTE 1 6 A 2 8 3 2 3 6 4 0 44 48 5 2 5 6 LITRES T T T T T T T T PER MINUTE 6 1 3 L 10 6 12 1 13 6 15 1 16 7 18 2 19 7 212 CURVES REPRESENT PUMP DISCHARGE ADJUSTED FOR INTERNAL BY PASS
20. s out and the chiller automatically restarts Call a qualified refrigeration service technician for service LOW REFRIGERANT PRESSURE red This indicator lights if the refrigerant pressure drops below a safe level The compressor will stop and remain off until the pressure reaches a safe level The light will go out and the chiller will then resume operation automatically LOW WATER FLOW red SMC units without pump only This indicator lights if the flow switch senses chilled water glycol flow through the evaporator dropping to an unacceptable level The compressor will stop until the flow switch senses adequate flow and restarts the chiller 6 2 Switches POWER This switch energizes the control circuit it also turns off the chiller mm SMC Series Chillers Page 27 Figure 13 Optional Graphic Panel SMC Series Portable Chiller OW HIGH COMPRESSOR REFRIGERANT REFRIGERANT ON PRESSURE PRESSURE J SS Page 28 ED smc Series Chillers 7 Routine Maintenance 7 1 Lubrication Every three months grease all fan motors and pump motors that do not have permanently sealed bearings Remove grease relief plug motors only before adding grease Failure to do so may result in dislodging the bearing grease retainer eventually causing bearing failure Compressors are hermetically sealed no oiling is required 7 2 Condenser Maintenance Dirty condenser heat exchange surfaces reduce syste
21. t be sure VENTILATION is ADEQUATE PROTECT adjacent materials from flame or sparks by shielding with sheet metal An approved FIRE EXTINGUISHER should be close at hand and ready for use if needed The refrigeration system can develop refrigerant pressures in excess of 500 psi 3 450 kPa DO NOT CUT into the system without first relieving pressure Do not jump or bypass any electrical safety control Do not restore power until all tools test equipment etc have been removed and the panels replaced Only PROPERLY TRAINED personnel familiar with the information within this manual should work on this equipment mm SMC Series Chillers Page 3 Table of Contents 1 General Information 7 1 1 Introduction 1 2 Necessary Documents 1 3 Models Covered 1 4 Available Options 1 5 Uncrating Your New Chiller 1 6 ln the Event of Shipping Damages 1 7 Ifthe Shipment is Not Complete 1 8 Ifthe Shipment is Incorrect 1 9 Returns 2 Chiller Installation 13 2 1 Electrical Connections 2 2 Process Water Connections 2 3 SMC Condenser Air Supply 2 4 Water Reservoir 2 5 Overhead Process Considerations 3 Sequence of Operation 17 3 1 Chilled Water Circuit 3 2 Refrigeration Circuit 3 3 High Pressure Cutout 3 4 Low Pressure Cutout 3 5 Remote Start Stop Interlock Page 4 Rm SMC Series Chillers Table of Contents Startup Checklists asi on Ec eee 23 4 1 Introduction 4 2 SMC Pre Startup Checklist 4 3 SMC Startup Checklist
22. t Identification Heavy one piece plastic reservoir Fill drain sight glass for easy water level indication and control NEMA 1 enclosure with dependable rated components Insulated refrigerant lines Efficient insulated for increased efficiency pump and evaporator Air cooled condenser not shown Convenient chilled water supply and retum connections High and low Process bypass protection refrigerant pressure switches Thermal expansion valve Refrigerant sight glass Rugged dependable P asd reciprocating compressor Filter dryer D smc series Chillers Page 19 Figure 8 Piping Schematic 1 Pump with Reservoir Air cooled condenser Discharge line _ Liquid line a Refrigeration evacuation valve Relief valve Refrigeration evacuation valve 4 V Suction Filter Filter Line Drier Expansion Sight k valve l Evaporator 9293 Y 3 Legend Equalizing line Refrigeration lines P c Chilled water piping ie S ower siemen Condenser water piping efrigeration ba access valve End of unit piping Temperature Optional probe pressure High i TC gauge pressure S P To control Low A Process pressure control Bypass Optional ian CPR valve Compressor Refrigeration 1 access valve Vent Fill compressor mounted Sight glass Tank L p Drain ump Bara L From Process Page 20 ED smc Serie
23. ure control Bypass Optional N CPR valve Compressor Refrigeration access valve compressor mounted Flow Switch al PE From j Process Page 22 ED smc Series Chillers 4 Startup Checklists 4 1 Introduction Follow the check lists below for the startup of your new chiller These lists assume the installation information elsewhere in this manual has been read and followed New chillers should be started up and checked by a qualified refrigeration service technician 4 2 l DN IA dee co 4 3 SMC Pre Startup Checklist Check the shipping papers against the serial tag to be sure chiller size type and voltage is correct for the process that will be controlled Check the transformer primary voltage connections to be sure they are configured for the electrical power you are using The voltage at the main power connection must read within 10 of the voltage listed on the serial tag Electrical connections must conform to all applicable codes The chilled water TO PROCESS and FROM PROCESS connections should be completed Be sure the reservoir tank and chilled water circuit piping are filled with water The air cooled condenser should have an adequate supply of air for proper operation Connect main power to the chiller and run the chiller just long enough to see if the pump is generating normal pressure Check your work and proceed to the SMC Startup Checklist section below SMC Startup Checklist Turn ON th
24. y 180 psi 1 241 kPa for the SMC050A and SMC100A 275 psi 1 897 kPa for the SMC150A SMC Ambient Temperature Ranges Ambient temperature range Minimum temperature Maximum temperature 65 F 18 C 100 F 38 C 40 F 4 C 120 F 49 C 2 4 Water Reservoir During startup and when additional solution is required see Figure 5 on Page 17 for the recommended ethylene glycol water solution This chart shows the proportions needed to provide freeze protection to 20 F C below the desired process setpoint M Add a pre mixed solution to provide freeze protection to a temperature 20 F C below the normal operating temperature of the chiller M Use industrial quality not automotive ethylene glycol Page 14 Rm SMC Series Chillers A corrosion inhibitor suitable for the materials in the system should be added to the glycol water solution If straight water use is desired contact the Sterlco Engineering Department The six gallon 23 liter reservoir is not designed to withstand water pressure above 5 psi 34 kPa The fill opening and vent line must be vented to the atmosphere for proper operation E AN A Figure 5 Ethylene Glycol Curve Ethylene glycol required for evaporator freeze protection ETT TTT TTT SEIN OLLLLLI PLN ET Et Ethylene glycol percent 10 P 30 40 50 60 70 Chilled water operating temperature F set point Normal operating range is between 30 F and 70 F 0 0 0
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