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Sterling STERLCOOL CFP05-25A User's Manual

1. 33 Table of Contents ROUTINE MAINTENANCE 34 PUBRIGATON isis o mays AE SOLED pl Se 34 CLEANING AIR COOLED CHILLER FILTERS dad 34 CONDENSER MAINTENANCE 234930 e S64 a e488 as 34 ACOSO era ba eed AA AAA A OS a oe AA DRA 34 70 17 16 16510 1 15 vet er Hid e RUE SUR RE VON gt RA AS AA EAS RARAS 34 Table of Contents Sterling Inc Note Performance figures stated in this manual are based on a Standard Atmosphere of 59 F at 29 92 Hg 1013 2 millibars at sea level using 60 hz power Ambient air temperature is an important consideration in choosing a chiller Sterling Inc can advise you on proper selection and sizing of systems for your operating environment Sterling Inc 15 committed to a continuing program of product improvement Specifications appearance and dimensions described in this manual are subject to change without notice STERLCOOL PORTABLE CHILLER 1 SAFETY CONSIDERATIONS STERLCOOL Portable 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 Fol
2. RRR ime 846 in to Pump running in reverse Pump pressure low refer to curves for normal pressure for various pumps Sterling Inc STERLCOOL PORTABLE CHILLER 35 TROUBLESHOOTING CHECK LIST an F n s x PROBLEM CAUSE SOLUTION Freeze control set higher than liquid in sy stem below desired leaving temperature Defective freezestat Refrigerant low Check the refrigerant charge Sight glass should be clear while compressor runs Call for service if bubbling or foaming Pressure switch contacts open Clean the air filters Check condenser fans for proper rotation Check for dirty condenser Check for condenser air Refrigerant high pressure cut out switch contacts open obstruction Pump runs compressor will not Fan motor out on overload Defective fan cycling control Replace Defective fan motor Bos 6 PE ace Check for high low voltage Must be within plus or minus 1096 of nameplate rating Check for poor compressor electrical connections Compressor internal overload open Allow time to cool and reset Compressor contactor holding coil open Repair or replace Defective pump m
3. CFPIO A amp CIP15 A HAVE TWO FANS AS SHOWN CIPOS A CIPT 5 A HAVE ONE FAN PRESSURE AIR IN AIR IN GAUGE PROCESS FILL AND RETURN SIGHT GLASS PROCESS SUPPLY ELECTRICAL SERVICE RIGHT SIDE VIEW CFP20 A 8 CFP25 A AIR COOLED CHILLER OUTLINE DIMENSIONS REAR VIEW CFPOS W THRU CFP25 A Nominal Sac Chilled BIER Pipe Size Water Condense Shipping Length Width Height Cooled Chiller Model Number CFP20 A 1714 TS 18 000 Le 2 450 EI 1 5 915138 Based on 50 F chilled water supply temperature and 95 F ambient air temperature Consult factory for other requirements Flow rate based on 2 4 gpmi ton at 25 psi or higher Alternate pump sizes available Sterling Inc STERLCOOL PORTABLE CHILLER 7 INSTALLATION Check serial tag voltage and amperage requirements and make sure your electrical service conforms Total running amps for Portable Chillers can also be found in Tables 2 6 and 2 7 Bring properly sized power leads and ground from a fused disconnect installed by your electrician to 6 unit Use Fusetrons in the disconnect switch 51261 according to the National Electrical Code recommendations listed on the electrical schematic mounted inside the control enclosure door e ELECTRICAL CONNECTIONS MUST COMPLY WITH ALL APPLICABLE ELECTRICAL CODES e THE CHILL
4. 30 CONTROL PANEL INDICATOR LIGHTS 30 Green ED ached 0 75 AAA 30 gange OV LEO SAS is da rrr 30 OUT LED 4 xui OE AE AA SN EA EAS rp ue wea ae 30 OUT DEED w pa d peu pa SARS aei et Sa Ee ee iama ted 30 ATLED O usya Q Q suls pu a See We 30 PRIA LED e ek eh ei wee Sk ees ee a ao i OO ee ae eo Se 30 ALMUS EBD whee NAS n Soie or a a eee eee 30 CONTROLE PUSH BUTTONS cesan a a ACE SOS eds E A OR 31 Se Maronis a Tid 57 ae eee Et ASS A rcr Em 31 DONWBCATFEO w BU MOM br da a Og A ATA qeu x d pe SU ee ken 31 DB ATIOW BURO NAAA EISNER ASADA ed rt 31 FETE AITO WOON ib wen ee ES nC Eee Dos O US NU ep T ROPA EHR eben 31 MICROPROCESSOR CONTROL OPERA INTRODUCTION Haw soe 75 5 do P too do 32 HIGH REFRIGERANT PRESSURE LIGHT ee s 32 LOW REFRIGERANT PRESSURE LIGHT eee ah hen 32 LOW OL PRESSURE OUGHT i d i CRI Cae ee eae ce en T OS eo es ee a a 32 LOW WATER LEVEE LIGHT supe co BANE AS eee ae Rn a oe dE OR Sh OS Ru PE A deis 32 LOW WATER TEMPERATURE LIGHT ue uyu kipus atus CERES de oq A AA AA 33 SYSTEM POWER LIGHT sucia AE A
5. the necessary components for automatic make up and water treatment systems See Section 3 7 for more details 2 4 STERLCOOL PORTABLE CHILLER Sterling inc GENERAL INFORMATION 2 4 8 Low Ambient Fan Cycling Pressure Switch Applications with low ambient temperatures benefit from this option A pressure switch in the compressor cycles the primary fan OFFand ON in low ambient temperatures to maintain efficient condensing pressures o Portable Chillers are shipped mounted on a skid enclosed in a plastic wrapper and open crated on all four sides and top e Pry the crating away from the skid and remove Use a pry bar to remove the blocks securing the unit to the skid e 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 must be balanced on the forks Lift slowly and only high enough to clear the skid Use a pry bar if necessary to remove the skid from the unit Lowerslowly The unit will land on its casters and can be rolled into position CURVES REPRESENT PUMP DISCHARGE REFER TO O amp l MANUAL TO CORRECT FOR UNIT DISCHARGE Figure 1 60 Hertz Pump Curves Sterling Inc STERLCOOL PORTABLE CHILLER 5 GENERAL INFORMATION PIPE CONNECTION SIZES STD FLOW DBL FLOW CONDENSER PROCESS PROCESS TOWER OR CITY SUPPLY amp SUPPLY am
6. AA YY ZP 3 4 85 2 3 4 5 6 7 a 9 10 1 DESIGN GPM AND OP ARE BASED ON 2 4 GPM PER NOMINAL COMPRESSOR HORSEPOWER 2 ACTUAL CAPACITY IS BASE ON TONS GPM FORMULA FOR STRAIGHT WATER YSTEM NO ADDITIVES 3 A P READINGS ARE TAKEN DIRECTLY ACROSS EVAPORATOR PRESSURE DROP STERLCOOL PORTABLE CHILLER 9 INSTALLATION 3 2 5 WATER TREATMENT Water treatment is an integral part of any piping system In some locations raw water may be used in the system without problem in other locations it will result in large deposits of scale and corrosion Sterling Inc recommends consulting a professional water treatment specialist for a water treatment plan tailored to meet the requirements of your process Water cooled Portable Chillers can use either city or tower water as a cooling medium Allof the external piping and connections supplying and discharging water to and from the condenser should be full size 3 3 1 CONDENSER WATER IN The condenser water supply located at the rear of the Portable Chiller is the inlet for city or tower water Water should be supplied at a maximum temperature of 85 F and a minimum pressure of 25 psi A water regulating valve is a standard feature in the condenser water supply line Se THE WATER REGULATING VALVE IS FACTORY SET IT SHOUL 88 ADJUSTED EXCEPT BY A QUALIFIED REFRIGERATION Normal R 22 refrigerant condensing pressure with 85 F water at 25 p
7. CONSIDERATIONS A GENERAL INFORMATION o INTRODUCTION az caruit kh OEE domno aod eat aede Sob Rates mei dade e d Mb ci 3 NECESSARY DOCUMENTS 45 2 59 7 sil CREER a IECUR EROR Med ua ees 3 MODELS COVERED o SR mee A CUR ISI s RES Guide are ESS 3 AVAILABLE OPTIONS o ave ua eoe c COR ii Ai Eos dose a 4 Oparating Vollages osi ee x eh CERE ne Ce woe de Se poses 4 Cooling RANGES run u ver v dou ep x Rp o MCA c db tb REI RIA ARIAS SEI LE 4 intake AIF FIHGES 0 920 I Sar Ea dieran de Y pode ds ai a de iet e pre 4 Special PUMPS iude E qae a oboe Rod Ru Oe ROS AAA do Wa bed qr des 4 FieserVollS ceu pu ue NUS E eor A mE SEE EU den ue diaper dan qd a ark B SN Q dac cera et 4 Static FANS sis ALANNA KER og Mate e dem 0 tue I qs eo duas Qo eco Redi Saba b mak Suma aw anu 4 Automatic Make Up Systems sese 4 Low Ambient Fan Cycling Pressure Switch eer 5 RINGERS TING rotas apukun paq saan dd oe eee eee eee ee ae 5 WATER COOLED PORTABLE CHILLER 5 3 5 6 AIR COOLED PORTABLE CHILLER 5 3 85 7 ELECTRICAL CONNECTIONS 4453 244 d RUE EA ED sa us saa A ae Be Sa 8 PROCESS WATER CONNECTIONS ALL MODELS 8 TO ROC La A A id
8. a water glycol mixture The water glycol mixture should provide for freeze protection to at least 20 F below the desired leaving water temperature The air cooled condenser should have an adequate supply of air for proper operation Connect the main power to the unit and bump start it to check for proper rotation direction If the pump is operating backwards reverse any two main power leads at the incoming terminal block The crankcase heater should be ON for at least 24 hours before start up to force dissolved refrigerant gas from the compressor oil e Check your work and proceed to Start Up in the next section Turn ON the chiller and put it under a process load e Set the Control to the desired process temperature using the shift set and up or down arrow buttons Adjust the Freezestat Cut Out dial located above the electrical enclosure to 10 F below the desired process temperature 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 any leaks and listening for unusual noises or vibrations that could indicate improper operation 28 STERLCOOL PORTABLE CHILLER Sterling Ine CONTROL OPERATION The control is an easy to operate microprocessor based PID control When the process reaches the Set Point the PID control in the cycles the hot gas bypass valve to maintain the proper leaving water temper
9. in the Electrical Enclosure for Unit Specific Details FUSED DISC BY OTHERS mE us m 112 COMPRESSOR T NE 1713 EARTH E 0 5 8 PANEL GROUND REMOTE START STOP BY OTHERS TERE ON OFF JUMPER 15 1 Hd OVERLDAD 3k ot 2 POWER ON Lo Bi T 5 LOW WIR Tew LOW PRES Hi PRES LOW Oi PRES INN e ATER 65 AT ow oc 6 SLT rz 01 PRESSURE Eto IPS SH 19 4 COMPRESSOR 2PS 1 CONTROL T RELAY fi TEMPERATURE CONTROLLER CONTROL RELAY 2 2 BYPASS 22 STERLCOOL PORTABLE CHILLER Sterling Inc SEQUENCE OF OPERATION Figure 15 Typical CFP Air Cooled Port able Chiller Electrical Sche matic Refer to the Schematic Mounted in the Electrical Enclo sure for Unit Specific Details ITT M 111 el 1n mi CARTH GROUND SUB PANEL GROUND REMOTE START STOP BY OTHERS rita ON OFF JUMPER 1S Y 3 a E f U T LOW WIR TEMP LOW PRES HI PRES LOW OIL PRES XININ X STARTER AT ALT 51 SLI SINN OlL PRESSURE fe E zi 5 1TAS COMPRESSOR O ama am i a Can C a 318 0 CONTACTOR 265 FAN P5 STARTER ji FAN STARTER 02 14 CONTROL RELAY fi TEMPERATURE CONTROLLER CONTROL RELAY j2 Sterling Inc STERLCOOL PORTAB LE CHILLER 23 ELECTRO MECHANICAL COMPONENTS The Freezestat is a safety feature that will shut down the c
10. obse E aote ter mean de mana gud 16 FHEEZESTAT CONTROL sureste iia cR RE OE dC acer P eS es 24 CRANKCASE FEA IER as ros ad OR ts EA UR ID REL die ete ead 24 HIGER PRESSURE CUTOUT uscar d aburrida d dtes p Erano ee Eee ros e ER 24 LOW PRESSURE CUT OUT vai e RR Ed TEMERE SEER AAA AA 24 OIL PRESSURE SWITCH 15 20 25 30 HP Compressors 25 FAN CYCLING SWITCH Air cooled Models Only 25 GEPO5S A dna DEPL OSA T iu Rua ERE IE A abo x AA EGA A 25 CFP10 A Through CFP25 A DT Tcr 25 CFP10 A Through CFP25 A with Optional Fan Cycling Switch 25 FLOAT SWIC nada kausa uwa ier ed dod oa d de 25 REMOTE START STOP INTERLOCK ssw ss wa RR de e AA A 26 INTRODUC HON o runs dte S CUTS ture c a eee ee ee So Ra ae 27 Table of Contents WATER COOLED CHILLER START UP CHECKLIST A ew 27 WATER COOLED CHILLER START UP 27 AIR COOLED CHILLER START UP CHECK LIST 28 AIR COOLED CHILLER 5 8 ee 28 CONTROL OPERATION 29 THE MICROPROCESSOR CONTROL 29 CONTROL OPERA TION RANGE ACAD Ree i n ed
11. up to force dissolved refrigerant gas from the compressor oil Check your work and proceed to Start Up in the next section OOLED CHILLER START UP e Turn ON the chiller and put it under a process load o Set the Control to the desired process temperature using the shift set and up or down arrow buttons e Adjust the Freezestat Cut Out dial located above the electrical enclosure to 10 F below the desired process temperature Check the pump amp draw and pump pressure The amp draw reading must be within the running load and service factor amps Sterling Inc STERLCOOL PORTABLE CHILLER 27 START UP CHECK LISTS Operate the chiller looking for leaks and listening for unusual noises or vibrations that could indicate improper operation 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 e The chilled water To Process and From Process connections should be completed The chilled water supply valve on the chiller must be open Be sure the reservoir tank and chilled water circuit piping are filled to the full mark with
12. whenever the temperature at the To Process thermocouple drops 2 F or more below the process Set Point The compressor is shut down until the process temperature is regained 30 STERLCOOL PORTABLE CHILLER Sterling Inc CONTROL OPERATION 7 4 1 SET BUTTON This button is used along with the arrow butttons to set the process set point When the Set button is pressed the four orange set point LEDs glow The brightest LED on the right may then be adjusted with the up or down arrow buttons Press the left arrow button to highlight the next LED to the left When the desired process set point is displayed press the Set button again 10 accept the new set point If the Set button is pressed but no attempt is made to change the set point the display will return to the original set point The microprocessor control will not accept a set point outside of the control s operating range 7 42 DOWN ARROW BUTTON This button lowers the value of the currently highlighted SV LED This button raises the value of the currently highlighted SV LED 7 8 8 LEFT ARROW BUTTON This button highlights each SV LED in succession Press it once to move one LED to the left The highlight will wrap to the starting point after the leftmost LED is highlighted To Change Set Point e Press the Set button o Press the up or down arrow button to change the highlighted LED to the desired value e Press the left arrow button to highlight th
13. years of reliable operation To get the most satisfaction from your new chiller read and follow the instructions in this manual The following documents are necessary for the operation installation and maintenance of STERLCOOL s Portable Chillers Additional copies are available from Sterling Inc Familiarize the appropriate personnel with these documents e This manual The electrical schematic and connection diagram mounted inside the control enclosure Typical schematics for general reference are provided in Figures 14 and 15 The operation and installation manuals for installed accessories and options The Customer Parts List included in the information packet Sterling Inc This manual provides operation installation and maintenance instructions for STERL COOL Portable Chillers Model numbers can be found on the chiller s serial tag Please know the model number serial number and operating voltage of your chiller if you need to contact Sterling Inc Portable Chiller models are designated by compressor horsepower 5 714 10 15 20 25 and 30 and the cooling method used For example a five horsepower air cooled portable chiller is designated CFPOS A a water cooled five horsepower unit is a CFPOS W sizes are available with either cooling method with the exception of the 30 horsepower which is available in the water cooled configuration only STERLCOOL PORTABLE CHILLER 3 GENERAL INFOR
14. E u HOT GAS BY PASS SOLENOID VALVE SIGHT 7 GLASS S FILTER H WATER DRIER REGULATING VALVE gt TOWER OR CITY WATER RETURN ee TOWER OR CITY WATER SUPPLY SHUT OFF VALVE LEGEND REFRIGERATION LINES CHILLED WATER PIPING CONDENSER WATER PIPING END OF UNIT PIPING CFP PIPING DIAGRAM ONE PUMP NO TANK Sterling Inc STERLCOOL PORTAB LE CHILLER 19 SEQUENCE OF OPERATION Figure 12 Two Pump No Tank CFP Portable Chiller Piping Dia gram SUCTION amp DISCHARGE SERVICE VALVES SEMI HERMETIC COMPRESSORS ONLY RECIRC PUMP PUMP SWITCH FT suction SEMI HERMETIC AO LINE COMPRESSORS ONLY SWITCH ELEMENT PROCESS sn sus Lus ene pee Lo EQUALIZING LINE I DL FROM Sasi J PROCESS SHUT OFF VALVE PRES GAUGE ky 5 PROCESS TEMPERATURE PROBE ACCUMULATOR FREEZESTATL OH POWER E VALE SIGHT SHUT OFF HOT GAS BY PASS VALVE SOLENOID VALVE E RELIEF ANGLE WATER FILTER DRIER DISCHARGE LINE VALVE VALVE REGULATING 53 7 VALVE WATER COOLED CONDENSER NOTE a DIAGRAM REPRESENTS WATER LIQUID LINE Vespa LIQUID NE AIR COOLED CONDENSER VE DISCHARGE FROM COMPRESSOR LIQUID CFP PIPING DIAGRAM TWO PUMP NO TANK 20 STERLCOOL PORTABLE CHILLER K LEGEND CHILLED WATER PIPING CONDENSER WATER P
15. ER MUST BE GROUNDED IN ACCORDANCE WITH NEC ARTICLE 250 o VOLTAGE MUST BE WITHIN 10 OF NA MEPLATE RATING 3 2 1 TO PROCESS The chilled water supply labeled TO PROCESS is the outlet for the chilled water leading to the process being cooled 3 2 2 FROM PROCESS The chilled water return labeled FROM PROCESS is the inlet leading from the process back into the chiller to be cooled and re circulated 3 2 3 PROCESS WATER CONNECTION SIZING CONSIDERATIONS All external chilled water connections to the process must be of adequate size See Tables 2 6 and 2 7 for sizing recommendations The largest possible openings and passages should be provided for the flow of chilled water through platens dies molds or other pieces of equipment It is extremely important to have a minimum pressure drop external to the unit 3 2 PROCESS WATER BY PASS VALVE Portable Chillers have a spring loaded by pass valve used as a safety feature 8 STERLCOOL PORTABLE CHILLER Sterling Figure 2 Condenser GPM Pressure Drop Curves Figure 3 Evaporator GPM Pressure Drop Curves Sterling Inc INSTALLATION If the chilled water shut off valves are inadvertently closed while the chiller is running the factory set by pass valve will open and allow a small amount of water to flow through the chiller This protects the chiller from freeze up and allows the other safety features to remain effective The by pass valve should no
16. IPING END OF UNIT PIPING TOWER OR CITY WATER RETURN TOWER OR CITY WATER SUPPLY SHUT OFF VALVE Sterling inc SEQUENCE OF OPERATION Figure 13 No Pump No Tank CFP Portable Chiller Piping Dia gram A SUCTION amp DISCHARGE qe SERVICE VALVES SEMI HERMETIC COMPRESSORS ONLY CNTL L PRES CNTL SHUT OFF RES VALVE E O E pamapa eene lt 1 FRM ss SEMI HERMETIC PRES COMPRESSORS ONLY GAUGE FN FLOW TEMPERATURE 0 I n SWITCH PRO Er um DG PROCESS ACCUMULATOR El x FREEZESTAT C POWER 1 Ms EXPANSION ELEMENT VALVE EVAPORATOR EQUALIZING LINE SIGHT SHUT OFF HOT GAS BY PASS VALVE SOLENOID VALVE FILTER RELIEF ANGLE WATER DRIER DISCHARGE LINE VALVE VALVE REGULATING mr TOWER OR CITY AE RETURN WATER COOLED CONDENSER 3008 OR CITY WATER SUPPLY NOTE DIAGRAM REPRESENTS WATER LIQUID LINE SHUT OFF AIR COOLED CONDENSER VALVE VALVE DISCHARGE LINE FROM COMPRESSOR LEGEND REFRIGERATION LINES LIQUID 1 CHILLED WATER PIPING UNE CONDENSER WATER PIPING TO SHUTOFF VALVE END OF UNIT PIPING J CFP PIPING DIAGRAM NO PUMP NO TANK Sterling Inc STERLCOOL PORTABLE CHILLER 21 SEQUENCE OF OPERATION Figure 14 Typical Water Cooled CFP Portable Chiller Electrical Schematic Refer to the Schematic Mounted
17. MATION Portable Chillers are available with options that tailor the unit to your requirements Some are factory installed some can be retro fitted in the field Consult your sales representative 2 4 1 Operating Voltages Portable Chillers are available configured for 208 230 3 60 380 415 3 50 460 3 60 515 3 50 575 3 60 volts 2 4 2 Cooling Ranges Portable Chillers are offered in two cooling ranges R 22 charged chillers cool 20 F to 70 F processes Low temperature R 502 units are used with 07 to 30 F processes 2 4 3 Intake Air Filters Intake air filters are highly recommended for air cooled Portable Chillers 2 4 8 Special Pumps Special pump options are available for greater pressure and flow rates One and two pump configurations with 114 3 5 7 and 10 horsepower pumps are offered 2 4 5 Reservoirs A 40 gallon reservoir is standard Water cooled Portable Chillers are available without a reservoir for processes that use their own reservoir 2 4 6 Static Fans Static fans are available for installations where the exiting air is to be exhausted though ductwork They are available on 5 through 15 horsepower air cooled Portable Chillers and may be field retro fitted without sheet metal modification 2 4 7 Automatic Make Up Systems This option includes a float valve in the reservoir and the necessary solenoid valve and pipe fittings to connect a Portable Chiller to an automatic make up system Sterling Inc offers
18. Make Up connection is factory installed Refer to Figure 7 for the additional components necessary for this installation Your piping must provide backflow protection to protect city water supply and prevent over pressuriza tion of the reservoir WARNING PREVENT RESERVOIR OVER PRESSURIZATION BY SETTING THE REQUIRED PRESSURE REGULATING VALVE TO LIMIT MAKE UP WATER PRESSURE TO LESS THAN 5 PSI THE RESERVOIR MUST REMAIN VENTED TO THE ATMOSPHERE WARNING IF THE AUTOMATIC MAKE UP SYSTE CITY WATER SYSTEM PROVISIONS MUST ACKFLOW CONTAMINATION AN APPRO REVENTER MUST BE INSTALLED IN ACCORDANCE WITH LO ODES PRESSURE REGULATING EON VALVE PREVENTER SOLENOID L N valve UWA I T N WATER MAKE UP FLOAT SWITCH M LOW LEVEL FLOAT SWITCH RESERVOIR TANK X DRAIN AUTOMATIC CITY WATER MAKE UP INDICATES END OF UNIT PIPING 14 STERLCOOL PORTABLE CHILLER Sterling Inc INSTALLATION Figure 8 Recommended Gly colWater Solution Percent ages for a Range of Process Temperatures Sterling Inc AVOIDI IN GR icz ZEZE E a cl P WARNING THE ADDITION OF STRAIGHT CITY WATER INTO A IGLYCOL WATER MIXTURE WILL DILUTE THE SOLUTION AND x IEVENTUALLY LEAD TO SYSTEM FREEZE UP DAMAGE FROM FREEZE UP IS NOT COVERED BY THE STERLING INC WARRANTY To prevent system freeze up in Automatic Make Up applications a system to
19. STERLCOOL PORTABLE CHILLER Service and Instruction Manual Models CFPO5 W through CFP30 W and CFPOS A through CFP25 A STERLING INC 5200 West Clinton Avenue P O Box 23435 Milwaukee Wisconsin 53223 0435 Manufacturers of Temperature Control Equipment Since 1916 from defects in workmanship and material when used under the conditions recommended by STERLING INC The Company s obligation under this warranty is limited to make good at its factory any parts which shall within one 1 year after delivery of equipment of its manufacture to the original purchaser be returned to STERLING INC with transportation prepaid and which its examination shall dis close to its satisfaction to have been defective The Com pany neither assumes nor authorizes any other person or persons to assume for it any liability in connection with the sale of its equipment except under the conditions of this warranty This warranty does not cover any labor charges for replace ment of parts adjustments repair nor any other work done This warranty shall not apply to any apparatus which in its opinion has been subjected to misuse negligence tem peratures or pressures in excess ofthe limits recommended by the Company or which shall have been repaired or altered outside the Company s factory Replacement of defective material will be F O B our factory Replacement of component parts not of its manufacture will Table of Content SAFETY
20. T PROBLEM CAUSE SOLUTION Check main disconnect fuses wiring and power lead to unit No power Voltage must be within plus or minus Wrong voltage supplied to the unit 1096 of nameplate rating Unit will not Run Replace check transformer Check crankcase heater Add anti freeze solution as required to bring liquid level up to normal Pump motor off on overload Reset and test Lower set point to 10 F below desired leaving water temperature Control circuit fuse blown Reservoir float switch circuit open Pump runs compressor cycles at short intervals Freeze control setting too high Be sure the antifreeze mixture protection is right for the process The leaving water temperature is too high x x Refrigerant charge is low Call service to find and repair the leak Call service to adjust the pressure switch pressure control to 30 psi R 22 cut out and 50 psi cut in improper water glycol solution The refrigerant pressure switch is set too high Verify proper rotation if incorrect reverse any two main power leads Re verify for correct rotation Check for foreign matter Clean the system rm ane re re m dan mma ame e
21. VALVE REGULATING 4G amp 1 VALVE E N E E zie OR i WATER COOLED P WATER RETURN CONDENSER TOWER OR CITY WATER SUPPLY l i i d NOTE DIAGRAM RI PRESENTS WATER LIQUID LINE SHUT OFF COOLED CONDENSER REUEF VALVE j I y DISCHARGE LEGEND FROM COMPRESSOR 3 REFRIGERATION LINES s QUID r E CHILLED WATER PIPING epee ae lu a CONDENSER WATER PIPING END OF UNIT PIPING TO SHUTOFF VALVE CFP PIPING DIAGRAM TWO PUMP 18 STERLCOOL PORTABLE CHILLER Sterling Inc Figure 11 One Pump No Tank CFP Port able Chiller Piping Diagram SUCTION amp DISCHARGE SERVICE VALVES SEMI HIGH L HERMETIC COMPRESSORS ONLY PRES CNTL LOW PRES CNTL SUCTION SEMI HERMETIC LINE COMPRESSORS ONLY x SWITCH PUMP FLOW ACCUMULATOR SWITCH POWER g ELEMENT SHUT OFF VALVE RELIEF VALV KF Oo WATER COOLED ANGLE sa n e LL E paa CONDENSER NOTE 2 DIAGRAM REPRESENTS WATER COOLED UNIT RELIEF VALVE _AIR COOLED CONDENSER DISCHARGE FROM COMPRESSOR LIQUID TO SHUTOFF VALVE gt TEMPERATURE EQUALIZING LINE SEQUENCE OF OPERATION SHUT OFF VALVE De FROM PROCESS PROBE i Dk PROCESS FREEZESTATL J4 EXPANSION E VALV
22. VE RESERVOIR FIELD PIPING FOR CENTRAL SYSTEM INSTALLATION WITH OVERHEAD SUPPLY AND RETURN IDO NOT CONNECT MAKE UP WATER DIRECTLY TO THE CHILLED WATER RESERVOIR UNLESS AN APPROVED AUTOMATIC WATER The reservoir is not designed to withstand water pressure in excess of 5 psi The fill opening and vent line must be vented to the atmosphere for proper operation The optional automatic make up system is described in the next section If your application has chilled water or process piping above the reservoir fill and vent level install a standpipe to a point one foot above the highest point in the system In applications where the process or its piping is 15 feet or more above the reservoir steps must be taken to prevent over pressurization of the reservoir This condition can occur on system shut down when the water in ihe 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 for details NOTE The reservoir s reserve capacity can hold a maximum volume equal to 25 feet of 2 inch pipe Sterling inc STERLCOOL PORTABLE CHILLER 13 INSTALLATION Figure 7 Optional City Water M Up Piping Schematic The Portable Chiller may be connected to an automatic make up system if the optional package float switch pipe fittings solenoid valve pressure regulating valve and 1 2 NPT City Water
23. abd des VR dirae M EIA A aes 8 FIOM PIOCESS 3 24 e EH A AA Sd doe AAA TO apa VC AREA eA 8 Process Water Connection Sizing Considerations nnn 8 Process Water By Pass Valve o 8 Water realment uy va ys x tdeo aot us QUE D SU d a s ARAS PAR eq de e Ne 10 WATER COOLED CONDENSER WATER 5 10 Condenser Water Iy iweb eee eerie AA AAA ou tel d 10 Condenser Water QUE resaya Y ER E 9 sU NC Se OE RAS ett ed 10 Table of Contents AIR COOLED CONDENSER AIR SUPPLY ee ee dd RE CR A S 10 Condensing Air Terperdtufe Ra ERTIES ae ea as a a ata MES 12 MOTOR DIRECTION CHECK 2 amp 2 xk ara a a ri EU h huy ELE 12 COMPICSSO Z LES k Ries be a td n RIT TET a Pon 12 Water PUID us ae oe psi ae ati dae Ge a SS EE 12 C ndensel EAT OAR donde nod VERA AE AA ax Rs SA 12 WATER RESERVOIR 5 53 49 AA Eee eh eee Ee es 12 AUTOMATIC WATER MAKE UP OPTION E 0 a 14 AVOIDING FREEZE UP WITH AUTO MAKE UP 15 Ghemical Feeder s au tora ds bx a qd seo dde odi Uo di 15 Make ID Reservoir uyu abite ai es dish eet hr Rc os 15 CHILLED WATER CIRCUIT REFRIGERATION CIROULE ENS SCE RS
24. ature The control has been fully factory tuned and tested The control is configured at the factory and needs no adjustment Set the desired process temperature Set Point and the control does the rest Figure 17 The Microprocessor Control REX C900 LE CHILLER 29 Sterling Inc STERLCOOL PORTAB CONTROL OPERATION Standard R 22 Optional 8 50 Portable Chillers Portable Chillers 20 to 70 F 0 to 30 F 7 3 1 GREEN PV LED The large green numeric LED display on the face of the control displays the actual process temperature at the To Process thermocouple 7 3 2 ORANGE SV LED The orange LED display on the face of the control displays the desired process Set Point 7 33 OUT 1 LED The green OUT 1 LED lights whenever the hot gas bypass feature is operating 7 3 4 OUT 2 LED The yellow OUT 2 LED is not used in the Portable Chiller microprocessor control 7 3 5 AT LED The green AT Auto Tune LED flashes during the Auto Tune sequence The microproces sor control has been tuned at the factory no field auto tuning is needed 7 3 6 ALM 1 LED The ALM 1 red LED lights whenever the temperature at the To Process thermocouple rises 2 F or more above the process Set Point The compressor will turn on and run until the process Set Point has been achieved This 2 F control point is factory set for proper compressor operation 7 3 7 ALM 2 LED The ALM 2 red LED lights
25. densing pressures If the optional fan cycling switches are installed the primary fan FAN 1 turns on at 250 psi and off at 200 psi FAN 2 cycles on at 275 psi and off at 225 psi Sterling Inc STERLCOOL PORTABLE CHILLER 25 ELECTRO MECHANICAL COMPONENTS This safety feature shuts down the system if the water in the reservoir falls below a safe level Pump cavitation and freeze up would otherwise occur An additional contact is provided to allow the remote starting or stopping of the Portable Chiller from a remote location To use this feature remove the jumper between terminals X1 and 1 on TB2 Supply a switch or dry contact interlock connected in series between these two termunals Refer to the schematic glued inside the control enclosure door or the typical schematics in Figure 14 OIL PRESSURE Figure 16 HIGH LOW SWITCH FAN CYCLING FAN CYCLING FREEZESTAT Typical CFP Portable Chiller PRESSURE PRESSURE CFP15 THRU 30 PRESSURE PRESSURE SWITCH SWITCH SWITCH 1 SWITCH 42 ue LAVON Qu CFP A ONLY OPTIONAL 8 YL MAIN POWER TERMINALS CONTROL TERMINALS d amp l e e 51 ange die e 5 Ola 6 1 8 1 8 911 91 COMPRESSOR FAN MOTOR FAN MOTOR CONTACTOR PUMP STARTER STARTER STARTER CFP A ONLY RELA YS los TYPICAL SUB PANEL LAYOUT 26 STERLCOOL PORTABLE CHILLER Sterling Inc START UP CHECK LISTS Follow the check lists below for the start u
26. e next LED to the left if desired Use the up or down arrow buttons to change the highlighted LED s value e Press the Set button to accept the new setpoint The new set point will be displayed To abort the change do not press the set button the previous set point will return Sterling Inc STERLCOOL PORTABLE CHILLER 31 GRAPHIC PANEL 8 0 1 INTRODUCTION This Section describes 6 indicator lights installed on the graphic control panel Refer to Figure 18 for the indicator light locations 8 0 2 HIGH REFRIGERANT PRESSURE LIGHT This indicator lights if the condensing pressure exceeds 350 psi The chiller will go into an idle mode until the High Pressure Cut Out is manually reset Call a qualified refrigeration service technician for service REFRIGERANT PRESSURE LIGHT This indicator lights if the refrigerant pressure drops below a safe level The compressor will will stop and remain off until the pressure reaches 70 psi The light will go out and the chiller will then resume operation automatically OIL PRESSURE LIGHT This indicator light installed on chillers with 15 horsepower compressors and larger lights if compressor oil pressure drops to a dangerously low pressure level After two minutes of low oil pressure the Portable Chiller will shut down This is a manual reset control Call a qualified refrigeration service technician for repairs 8 0 5 LOW WATER LEVEL LIGHT This light is illuminated when the floa
27. ged vertically from the chiller To change rotation direction e Disconnect and lock out power at the fused disconnect Reverse any two motor leads at the power source e Do notswitch leads at the motor or motor starters Portable Chillers are shipped with an antifreeze solution to protect against freeze up damage in transit The reservoir will have a solution of 70 water and 30 ethylene glycol during the summer months and 5046 water and 5046 ethylene glycol during the winter months During start up and when additional solution is required refer to the recommended ethylene glycol water solution curve in Figure 8 Add a pre mixed solution of industrial quality not automotive ethylene glycol and water to provide freeze protection to a temperature 20 F below the chiller s normal operating temperature For corrosion protection an inhibitor suitable forthe protection of the materials in the system should be added If straight water use is desired contact the Sterling Inc Engineering Department 12 STERLCOOL PORTABLE CHILLER Sterling Inc INSTALLATION 1 THE RESERVOIR VENT amp FILL LINE Figure 6 POINT Or SYSTEM THE VENT LINE Typical Field Piping for Over MUST REMAIN OPEN TO THE ATMOSPHERE VENT FILL head Process Supply and Return e MIN PROCESS RETURN PROCESS SUPPLY PIPING MUST BE ADEQUATELY SIZED FOR MINIMUM CFP CHILLER PRESSURE DROP ADD CHECK VALVE IF SYSTEM PIPING EXTENDS 15 FEET ABO
28. low 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 Itis 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 equipment 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 1 needed The refrigeration system can develop refrigerant pressures in excess of 500 PSI DO NOT CUT into the system until pressure has been relieved 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 2 STERLCOOL PORTABLE CHILLER Sterling Inc GENERAL INFORMATION STERLCOOL s Portable Water Chillers are reliable accurate and easy to use process cooling units They are available in both air and water cooled designs in a range of sizes from 5 to 30 horsepower All are self contained fully assembled and shipped ready to use A properly installed operated and maintained Portable Chiller will provide many
29. ompressor should the chilled water temperature approach the freezing point The chilled water pump will continue to run The freezestat cut out temperature is factory set at 40 F This is correct for a supply water temperature of 50 F the rated capacity operating temperature If lower chilled water temperatures are desired the process water must be mixed with industrial grade antifreeze See Figure 8 to provide protection down to 20 F below the desired operating temperature The freezestat cut out temperature can then be reset to a temperature 10 F below the desired operating temperature UTION FREEZESTAT ADJUSTMENT M 1 5 I JUALIFIED REFRIGERATION SERVICE TECHN Portable Chillers have a crankcase heater wired through the control transformer which operates continuously whenever power is applied to the chiller ENERGIZE THE CRANKCASE HEATER FOR 24 HOURS START UP TO DRIVE DISSOLVED REFRIGERANT I COMPRESSOR OIL FAILURE TO DAM IE I COMPRESSOR This electro mechanical safety feature opens the control circuit if the system condensing pressure exceeds 350 psi HIGH PRESSURE CUT OUT IS A MANUAL RESET CONTROL CALL 1 IA REFRIGERATION SERVICE TECHNICIAN TO ANALYZE THE PROBLEM 24 STERLCOOL PORTABLE CHILLER Sterling Inc ELECTRO MECHANICAL COMPONENTS This electro mechanical safety feature prevents the evaporator temperature from dro
30. only before adding grease Failure to do so may result in dislodging the bearing grease retainer which will eventually cause bearing failure Compressors are hermetically sealed and no oiling is required The usc and cleaning of optional filters is important to keep your Portable Air Cooled Chiller operating at peak capacity in contaminated air Clean them whenever they are dirty To clean slide the filter from its mount and hose down with clean water If the dirt is heavy use a mild dctergent and rinse well Allow the filter to dry completely before replacing it on the chiller Spare filters are recommended Use a spare while cleaning the other Blowing out a filter with compressed air does not satisfactorily clean it and may damage the filter WARNING Ster Dirty condenser heat exchange surfaces reduce system capacity 9 3 1 Air Cooled 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 will only make matters worse 9 3 2 Water Cooled Remove dirt in the condenser tubes with a nylon tube brush Mineral deposits can be removed by circulating liquid de scaling solution through the water side of the condenser Follow the directions on the container The refrigerant side is sealed and requires no routine maintenance 34 STERLCOOL PORTABLE CHILLER Sterling Inc TROUBLESHOOTING CHECK LIS
31. otor interlock to compressor control circuit Repair or replace Broken wire in the compressor control circuit Locate and repair Check for partially closed valves etc Be sure all lines are properly sized Restricted water flow Restricted condenser air flow Pump pressure is too high Clean filters Clean condenser Unit runs continuously but not enough cooling power Inefficient compressa Call service Unit under sized for dec p aida Call sales repete 36 STERLCOOL PORTABLE CHILLER Sterling Inc Lower freeze control temperature to 10 F me Reset and test
32. p WATER UNIT RETURN RETURN IN OUT CFP7 5 W CFP10 W 2 NPT 2 5 NPT PRESSURE GAUGE PROCESS RETURN PROCESS SUPPLY TOWER OR CITY WATER OUT TOWER OR CITY WATER IN FILL AND SIGHT GLASS DRAIN ELECTRICAL SERVICE 57 00 CFPOS W THRU CFPi5 W FRONT VIEW RIGHT SIDE VIEW m 2S CFP20 W THRU CFP3SO W REAR VIEW WATER COOLED CHILLER OUTLINE DIMENSIONS CFPO5 W THRU CFP30 W rT _ _ eee _ Q_ WATER COOLED PORTABLE CHILLER SPECIFICATIONS Nominal Cooling Chilled Standard Pipe Total Running Shipping City x Nom Length Width Height I 0 e ee s om mer w EA eter te tates tet te 55 55 e Rp RR Rm nm Based on 50 F chilled water supply temperature Water Cooled Chiller Model Number I Flow rate based on 2 4 gpm ton at 25 psi or higher Alternate pumps available Requirement based on availability of 70 F city water or 85 F tower water at 25 psi minimum Consult factory for other conditions 6 STERLCOOL PORTABLE CHILLER Sterling Inc GENERAL INFORMATION IOP VIEW IOP VIEW PIPE CONNECTION SIZES CFP 5 THRU 15 CFP 20 amp 25 A l STD FLOW DBL FLOW PROCESS PROCESS SUPPLY amp SUPPLY amp UNIT RETURN RETURN CFP7 S A 5 4
33. p 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 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 o 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 e The chilled water To Process and From Process connections should be completed o The chilled water supply valve on the chiller must be open Be sure the reservoir tank and chilled water circuit piping are filled to the full mark with a water glycol mixture The water glycol mixture should provide for freeze protection to at least 20 F below the desired leaving water temperature The tower or city condenser cooling WATER IN and WATER OUT connections should be completed and an adequate supply of condenser water must be available Connect the main power to the unit and bump start it to check for proper rotation direction If the pump is operating backwards reverse any two main power leads at the incoming terminal block The crankcase heater should be ON for at least 24 hours before start
34. pping below a pre set point It is factory set to open the control circuit at 30 psi for R 22 Low temperature chillers using R 502 are factory set to open the control circuit at 22 psi This permits 20 F operation with a 7096 water 3096 ethylene glycol coolant mixture This control automatically resets when the refrigerant pressure reaches 70 psi Low tempera ture units reset at 57 psi This safety feature is a differential pressure switch that monitors crankcase oil pressure If the oil pressure should drop to an unsafe pressure level for more than two minutes the switch will open the control circuit L PRESSURE SAFETY SWITCH A REFRIGERATION SERVICE TECHN 5 6 1 CFPO5 A and CFP7 5 A These models have one fan The fan cycling switch turns on the fan when the condenser pressure reaches 275 psi and turns it off when the pressure drops below 200 psi 5 6 2 CFP10 A Through CFP25 A These models have two fans One turns on every time the compressor operates and will continue to run if the compressor is shut down by the high pressure control The fan cycling switch turns on the second fan when the condenser pressure reaches 275 psi and turns it off when the pressure drops below 200 psi 5 6 8 CFP10 A Through CFP25 A with Optional Fan Cycling Switch Portable Chillers may be supplied with an optional fan cycling switch for applications with low ambient air temperatures This switch cycles fans ON and OFF to maintain efficient con
35. prevent recirculation of discharge air Discharge pants are required on CFP25 A and CFP30 A Figure 4 Typical CFPO5 A through ROOF CURB N AND FLASING CFP20 A Ductwork BIRD SCREENS AT BACKDRAFT DAMPERS ALL OUTSIDE VENTS 59 u Quis IDE VENTS A 2 ALL UNITS h FLEXIBLE CONNECTION 2 ALL UNITS Z INTAKE Y gt 6075 4 Figure 5 Typical CFP20 A ROOF CURB BACKDRAST DAMPERS es ALL OUTSIDE VENTS 4 CFP25A Ductwork AS REQUIRED x m S wr SE SEN ALL UNITS 20 al 25 8 i Sterling Inc STERLCOOL PORTABLE CHILLER 11 INSTALLATION 3 4 1 CONDENSING AIR TEMPERATURE Air cooled Portable Chillers are designed to operate at a minimum condenser entering air temperature of approximately 60 Operation of the equipment at a lower condenser entering air temperature can cause the low pressure cut out to shut down the unit due to the low refrigerant pressure It is recommended that the ambient temperature be maintained at 60 F or above 3 5 1 COMPRESSOR Portable Chiller compressors will run properly in either direction 3 5 2 WATER PUMP Correct pump rotation is indicated by a positive pressure of 20 to 30 psi on the To Process pressure gauge Check the pump curves in Figure 1 for Portable Chillers with special order pumps 3 5 3 CONDENSER FAN Air should be drawn through the condenser and dischar
36. replenish the glycol must be used Two methods are described below 3 8 1 Chemical Feeder Use a chemical feeder to meter glycol into the make up water and maintain the desired water glycol mixture Contact the Sterling Sales Department for more information on this equipment 3 8 2 Make Up Reservoir Glycol water solution may be mixed in a tank and used as a source of make up lluid Consult the Sterling Sales Department for more information on this piping configuration ETHYLENE GLYCOL REQUIRED FOR EVAPORATOR FREEZE PROTECTION 60 40 30 20 ETHYLENE GLYCOL PERCENT BY VOLUME 50 40 30 20 10 O 10 20 30 40 50 60 CHILLED WATER OPERATING TEMPERATURE F STERLCOOL PORTABLE CHILLER 15 SEQUENCE OF OPERATION Figure 10 Two Pump CFP Portable Chiller Piping Diagram SUCTION amp DISCHARGE SERVICE VALVES SEMI VENT de HERMETIC COMPRESSORS ONLY SIGHT GLASS OIL SS LOW LEVEL PRES SHUT OFF FLOAT SWITCH SWITCH sucrioN Kasi pk PRO SEMI HERMETIC AA LINE PROCESS COMPRESSORS ONLY TEMP PRES PROBE GAUGE PROCESS ACCUMULATOR PUMP pe s PROCESS POWER E EXPANSICN ELEMENTI VALVE Pa CA it i EVAPORATOR EQUALIZING LINE SIGHT SHUT OFF HOT GAS BY PASS VALVE SOLENOID VALVE FILTER RELIEF ANGLE DRIER WATER LJ _DISCHARGE LINE VALVE
37. si entering condenser water temperature is 210 psi 3 3 2 CONDENSER WATER OUT The condenser water return located at the rear of the chiller is the outlet for water after it has passed through the condenser It is connected to the tower inlet or to a sewer or other approved discharge receiver Air cooled Portable Chillers use the surrounding air to cool the condenser Install the chiller in an area where there is free passage of air for condensing and provisions for removal of heated air from the area Do not locate this chiller in locations where steam hot air or fume exhausts will be drawn into the chiller Air cooled condensers and filters must be cleaned frequently Failure to do so will result in reduced capacity increased operating costs and possible failure of the equipment See Section 9 for cleaning instructions Normal maximum R 22 refrigerant condensing pressure with 95 F air entering the condenser is 260 psi 10 STERLCOOL PORTABLE CHILLER Sterling inc INSTALLATION e The duct sizes in Figures 4 amp 5 provide maximum capacity do not reduce e Dampers to the outside must be closed whenever the fans or blowers are not operating Support the ductwork from the building structure not the chiller Maximum total external static load should not exceed 3 WG Provide 18 minimum clearance per side for the air intakes Backdraft dampers must be installed in the cycling fan blower discharge to
38. t be adjusted or tampered with CONDENSER GPM PRESSURE DROP CURVES CFPOS W 11 8 16 5 20 5 23 5 26 4 29 31 5 34 36 5 38 5 GPM DESIGN GPM PRE SSURE DESIGN AP 2 3 4 5 6 7 B 9 10 DROP CFP7 S w 16 24 30 35 40 44 48 51 58 GPM DESION QPM 225 HR pressure de RESSU DESIGN AP 1 8 4 2 5 4 5 8 7 8 9 10 DROP CFP10 w 16 24 30 33 40 44 48 51 S54 58 GPM DESIGN GPM 3 AAA AA AA A A YH ore RESSURE DESI 8 1 2 3 4 5 6 7 e 10 DROP 5 GPM DESIGN GPM 45 PRESSURE DESIGN AP 4 4 DROP CFP20 W SPM DESIGN GPM 60 PRESSURE R UR DESIGN AP 7 5 DROP CFP25 W 33 45 56 65 74 82 89 95 102 107 GPM DESIGN GPM 75 HA AA 9 YY PRESSURE DESIGN AP 5 2 3 2 3 4 s 6 7 a 9 10 DROP CFPSO W 33 45 56 65 74 82 829 225 102 107 GPM DESIGN GPM 90 PRESSURE DESIGN AP 7 2 8 gt 5 6 7 a 9 10 DR NOTES 3 2 DESIGN GPM AND AP ARE BASED ON 3 GPM PER NOMINAL COMPRESSOR Seen E ACTUAL GPM IS CALCULATED BY DETERMINO CHILLED WATER CAPACITY TON FORMULA FOR STRAIGHT WATER SYSTEM NO ADDITIVES 5 P READINGS ARE TAKEN DIRECTLY ACROSS CONDENSER CFPOS DESIGN DESIGN CFP7 S DESIGN DESIGN CFP10 DESIGN DESIGN CFP1S DESIGN DESIGN CFP20 DESIGN DESIGN CFP2S DESIGN DESIGN CFP3O DESIGN DESIGN NOTES EVAPORATOR GPM PRESSURE DROP CURVES SPM PRESSURE DROP GP MM PRESSURE DROP GPM PRESSURE ROP PRESSURE 10 DROP 51 4 73 83 9 1 9 9 108 114 120 GPM 72
39. t switch in the reservoir senses that the water glycol level has dropped below an acceptable level Add enough water glycol mixture to fill the tank to the operating level or check the operation of the automatic water make up if one is installed Use a mix that will provide freeze protection to at least 20 F below the process temperature 32 STERLCOOL PORTABLE CHILLER Sterling Inc Figure 18 Portable Chiller Graphic Panel Sterling Inc GRAPHIC PANEL 8 0 6 LOW WATER TEMPERATURE LIGHT This indicator lights if the chilled water drops below the Freezestat setting This prevents possible system freeze up The compressor will shut off and the chilled water pump will operate until the temperature rises above the Freezestat setting Warning The Sterling warranty does not cover damage due to system freeze up proper Freezestat setting will prevent freeze up e 8 0 7 SYSTEM POWER LIGHT This indicator lights whenever the power switch is in the ON position and the control circuit is energized Note The crankcase heater is energized whenever main power is applied to the chiller The position of the power switch does not affect the operation of the crankcase heater SYSTEM POWER Sterling Inc Milwoukee Wi STERLCOOL PORTABLE CHILLER 33 ROUTINE MAINTENANCE Every three months grease all fan bearings fan motors and pump motors that do not have permanently scaled bearings Remove grease relief plug motors

Sterling STERLCOOL CFP05-25A User's Manual

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