Home

HP A0554832 User's Manual

1. Mu we L1 COMPRES NTERNALLY THERMAL PROTECTED a 52 COMPRESSOR _____ 3 3L3 FLA 1 Z A OW FAN HP POWER WIRING l L1 ani NEG L2 4L2 8 4 1 1 1 E 34 E 1 113 513 i 3 1 4 113 WIRING 1L1 1 26 2 5 1 113 43 13 L1 N FA e e CHILLER REMOTE START STOP 213 211 1 xi 3 T8 Y BP I EXE ALARM SILENCE RELAY COMPRESSOR TEMPERATURE LED1 CNTL CHILLER PROCESS CONTROL 2 40 HP Portable Chillers Chapter 7 Appendix 71 of 78 Typical Power Wiring Schematic 5 through 40 Models 1DISC 108 1 111 COMPRESSOR INTERNALLY THERMAL PROTECTED 12 COMPRESSOR 173 1M 10L FUSE SIZE GROUNDING BAR X 211
2. 17 94 17 94 7 25 185 j i 34 00 OUTSIDE DIM 25x185 285 7 OUTSIDE DIM s 6 54 N EE P a 95 28 TOP VIEW 1 E E AIR IND lt AIR IN RESERVOIR VENT 1 x AurowarEn PROCESS PRESSURE GUAGE M MAKE UP SUPPLY OPTIONAL a a RESERVOIRFILL 91 43 BYPASS FILTER OPTIONAL ux N E e Es F 3 ELECTRICAL E e ENCLOSURE ET ire 7 N I _ N 6 68 gt 2 Z m e d PERERNOIRSIGHT GLASS C uf M BYPASS FILTER rLow l LEFT SIDE VIEW FRONT VIEW RESERVOIR DRAIN OPTIONAL I N d CONTROLLER WITH FROM PROCESS GRAPHIC AUDIBLE amp VISUAL ALARM OPTIONAL REAR VIEW 20 hp 25 hp and 30 hp air cooled portable chillers come standard with 4 101 mm swivel casters Process connections in NPT Dimensions pressor 1 Pump 2 Pump pump 1 pump in inches Dry Ship Oper ple to from 100 7 2 305 2 605 2 971 2 25 ars jars 20 914 1007 2 348 2648 3014 convert to multiply by 2 54 Add to height dimension based mounting options Weight is for standard chiller Some optional features will increase weight Multiply Ibs by 0 454 to calculate Kg Operating weight is w
3. convert to multiply 2 54 Add to height dimension based mounting options Weight is for standard chiller Some optional features will increase weight Multiply Ibs by 0 454 to calculate Kg Operating weight is with full 6 gallon 22 7 reservoir tank of water 2 40 HP Portable Chillers Chapter 7 Appendix 45 of 78 5 and 7 5 Air Cooled Portable Chillers Nominal operating parameters for air cooled models are 50 F 10 C leaving water temperature at 2 4 gpm per ton 9 1 lpm per 3 517 kW with 95 F 35 C ambient air For 50 Hz applications multiply capacity by 0 83 Nominal 60 Hz capacity flow rate must be maintained Nominal cooling Com Power in amps 460 3 60 capacity tons pressor Discharge air 9 1pump 2pumps hp openings cfm rated lrunning rated running Based on 50 F 10 chilled water supply temperature and 95 F 35 ambient air Optional additional process pump hp reduces chiller capacity by 0 2 tons per hp 0 703 kW ref cap per 0 746 kW pump power Based on 2 4 per ton 9 1 per 3 517 nominal 1 pump Customer use of ductwork requires optional high pressure fan for 5 hp to 15 hp 3 73 kW to 11 20 kW models An optional oversized process pump adds to the total rated or running chiller amperage To find the new total chiller amperage subtract the standard process pump amperage from the optional pump amperag
4. Low Refrigerant Pressure Light The Low Refrigerant Pressure light come on if the compressor suction pressure drops below the limit of the low pressure cutout switch The compressor shuts off but the pump s continues to run The indicator turns off and compressor restarts automatically when the refrigerant pressure rises to the limit of the low pressure cutout switch Call a qualified refrigeration service technician or contact the Service Department Low Oil Pressure Light The Low Oil Pressure light is installed on chillers with a semi hermetic compressor that have an oil pump differential pressure switch monitors the difference between crankcase pressure and oil pump pressure If the pressure drops to an unsafe level for more than two minutes the switch will open the control wiring circuit shutting off the compressor turning the light on but allowing the pump s to continue running This is a manual reset switch Call a qualified refrigeration service technician or the Service Department ON Control Power The green lighted sustained on Control Power Eom Lighted Switch Switch lights whenever the switch is in the ON POWER position and the control circuit 1s energized OFF Alarm Silence The red momentary on Alarm Silence Switch is Switch used to turn off the audible alarm on chillers that are M built with the audible or audib
5. 13 2 5 Optional Feature Sinne E e os e P re leet a eie ERES MUN due 14 CHAPTER 3 INSTALLATION 17 D MENU PER 17 3 2 Electrical aote tette teinte ete ER eee Db 17 3 3 Process Water Connections nnne nnne nenas 18 3 4 Bypass Valve 5 4 00 18 3 5 Galvanic Corrosion 2120 00 18 3 6 Water Treatment Considerations nennen nan 18 3 7 Condenser Considerations a a nanana arannana 19 Water Cooled Chiller 4 00 00 000000010000 19 Air Cooled Chiller 5 19 Remote Air Cooled Chiller Condensers a 20 38 Checking Motor Direction aa 24 Three Phase Compressors 24 Waler ire ER 24 Gondenser ka s um isis Lode eas 24 3 0 Water Reservolr ee hehe REE 25 3 10 Automatic Water Make Up 27 2 40 HP Por
6. 5 46 rm 49 28 d ix dy J 538 N 4 6 7 LL 6 06 4 CASTER 5 CASTER RAILS FEET MOUNTING DETAILS OPTICS PROCESS SUPPLY 94 00 ER OPTICS RESERVOIR VENT e OPTIONAL 7 MAKE UP SUPPLY OPTIONAL 7 A age EN TO PROCESS TOP VIEW PESOS Sias i CONDENSER WATER IN 1 1 TET 1 i L i E ELECTRICAL 34 65 D 28 y ons 1899 re 7 ENCLOSURE 27 18 24 18 __ pity 55 N NIN at N BYPASS FILTER SEE MOUNTING DETAILS 44 LEFT SIDE VIEW bf A0554820 FRONT VIEW OPTIONAL BYPASS FILTER FLOW METER RESERVOIR SIGHT GLASS Y RESERVOIR DRAN 1346 OPTIONAL m 4 83 FROM PROCESS AUDIBLE amp VISUAL ALARM j 15 71 OPTIONAL 18 77 REAR VIEW 2010 5 hp 7 5 water cooled chillers come standard with 4 101 mm swivel casters Process connections in NPT Com Dimensions no pump 1 pump no in inches Dry 2 tank height width Ibs Ibs T multiply by 2 54 Add to height amendon based on mounting options Weight is for standard chiller Some optional features will increase weight Multiply by 0 454 to calculate Kg Operating weight is with a full 20 gallon 76 liter reservoir tank of water 2 40 HP Portable Chillers Chapter 7 Appendix 50 of 78 10 hp and
7. refrigerant grade tubing high temperature brazed Install a customer supplied 400 psi approved refrigerant relief valve in the discharge line at the condenser following all codes When brazing copper joints flow dry nitrogen through the system to prevent carbon scale formation which causes contamination Isolate the refrigerant lines from the building preventing transfer of line vibration to the structure Do not secure the lines rigidly Leak check and evacuate the system down to 400 microns A decay of 50 microns after one hour is acceptable Warning To prevent injury or death due to explosion and or inhalation of phosgene gas purge system thoroughly while brazing refrigerant piping connections Use a pressure regulator in the line between the unit and the high pressure nitrogen cylinder to avoid over pressurization and possible explosion 2 40 HP Portable Chillers Chapter 3 Installation 20 of 78 System Configuration system configured of the arrangements shown page 62 of the Appendix The configuration and distance between the chiller and the condenser affects pipe size refrigerant charge oil return and oil charge Therefore there are limitations that must be adhered to for reliable and optimal operation e Leaving water temperature affects discharge line size Be sure to inform the installing contractor of the leaving water temperature range in which the chiller will be operating e The
8. _ gt p 4 IB 2 LO e 22 255 1 quum rosy c r INH I bod 52 3 Ammmd Chapter 7 Appendix sod I e CYLINDER U bz J 1 DWG 40562434 78 78
9. 2 1 Models Covered in This Manual 8 2 2 General Description usus cie Te uet eH ED TURAE 9 Chilled Water CirCUit eese eene nnne hern nsns sa rasan na 9 Refrigeration CIRCE P 9 2 3 Standard ee EE qe 10 Mechanical Fealures 000 10 Electrical Features o cette tie e Saabs 11 Refrigeration Feature Ssss Grrr naimen rpari 11 Controller Feal tes 5 rtt ed aya 11 Other Fealures ciu E A ire cce e 11 24 Safety Devices Interlocks eene enne enne nennene 12 High Low Thermostat rai esed ee en os enu en pudo 12 Grankcaseealer 5 el eot 12 High Pressure nct el Li ts UR te 12 Low Pressure 0 2 00 tassa tassa aas aaa 13 Oil Pressure Safety Switch 13 Fan Cycling Switch a 13 13 F IOWSSWIIGIIS w n a 13 Remote Start Stop Interlock
10. 26 r L x L 1CNTL 2 40 HP Portable Chillers Chapter 7 Appendix 73 of 78 Typical Wiring Schematic 5 hp through 15 Models without Pump r 4 I banned DWG A0554931 2 40 HP Portable Chillers Chapter 7 Appendix 74 of 78 Typical Wiring Schematic 20 hp through 30 hp Models with Pump I poo man 1 AQ DL CINE p 4 p 4 ONLY Ug pos My NT212 12 M Peed rey Leonel W 1 ou 1 K ma ma ma um um um um mm 2254 GAS benned DWG A0562343 2 40 HP Portable Chillers Chapter 7 Appendix 75 of 78 Typical Wiring Schematic 20 hp through 30 Models without Pump 2 40 HP Portable Chillers Chapter 7 Appendix gt DWG 40562435 76 of 78 Typical Wiring Schematic 35 and 40 Models with Pump 2 40 HP Portable Chillers ren rod 1 Lown Pon a 1 1 21871 rl reed kannad La p of d ISORI d al ONTR waru sama HOT CA banned gt DWG A0562344 Chapter 7 Appendix 77 of 78 Typical Wiring Schematic 35 hp and 40 hp Models without Pump 2 40 HP Portable Chillers my Uds od kanad
11. XU PUMP RECIRC PANEL GROUND Xy 213 FLA 2M 20L FUSE SIZE OVERCURRENT PROTECTION 311 BY OTHERS PROTECTED PER N E C 9 PUMP PROC x 26 an FUSE SIZE 4 M MOTOR INTERNALLY LOW AMBIENT 4 gt THERMAL PROTECTED AIR COOLED 3M 301 411 472 STANDARD AND 413 HIGH PRESSURE t XU AIR COOLED 4M 30L ie 512 LOCATED OUTSIDE 6T2 OF ENCLOSURE 613 WIRING BY OTHERS 3c m FUSESIZE OPTIONAL FEATURE HEATER 913 1H3 FUSESIZE FLA FUSE SIZE 1 2FU att im 2 tot 12 912 1 2 9 4 PROCESS gt E z l 1L3 9L3 1H3 FLA FUSE SIZE 0554815 FUSE SIZE 2 40 HP Portable Chillers Chapter 7 Appendix 72 of 78 Typical Wiring Schematic 5 hp through 15 Models with Pump OFF ON 3 IABLE SPEED MOTOR CONTROL 5 15HP FAULT ALARM RELAY OPTIONAL FAULT ALARM TIONAL PUMP OVERLOAD LED8 MAKE UP ENOID VALVE OPTIONAL HIGH TEMPERATURE LED3 CULATION PUMP STARTER PROCESS PUMP STARTER 4 52 JUMPER 4 50 VARIABLE SPEED 19 MOTOR 24 CONDENSER REMO DENSOR 2 RING CONT BINET 1
12. 15 Water Cooled Portable Chillers Nominal operating parameters for water cooled models are 50 F 10 C leaving water temperature at 2 4 gpm per ton 9 1 Ipm per 3 517 kW with 85 F 29 C tower water For 50 Hz applications multiply capacity by 0 83 Nominal 60 Hz capacity flow rate must be maintained Nominal cooling Power in amps water pres 460 3 60 flow City Tas e apie E he hp po ater water frated rated running rated running 15 3 Based on 50 F 10 C chilled water Supply 85 F 29 C ower water Optional additional process pump hp reduces chiller capacity by 0 2 tons per hp 0 703 kW ref cap per 0 746 kW pump power Based 2 4 gpm per ton 9 1 3 517 kW nominal 1 pump Based on availability of 85 F 29 C tower water at 25 psi 172 4 kPa 1 7 bars minimum Based on availability of 70 F 21 C city water at 25 psi 172 4 kPa 1 7 bars minimum An optional oversized process pump adds to the total rated or running chiller amperage To find the new total chiller amperage subtract the standard process pump amperage from the optional pump amperage see Figure 1 on page 16 and add it to the chiller rated or running amperage Multiply 460 3 60 amperage by 2 0 for 208 230 3 60 amperages 0609 69 28 EN 225 A 5 38 4 6 56 tL N 222 V N Pme 4 CASTE
13. 25 psi pressure for proper operation Connect the main 3 phase incoming power to the unit making certain that line one 1 is connected to the A phase line two 2 L2 is connected to the B phase and line three 3 L3 is connected to the C phase Check for proper rotation direction of fan s and pump s 2 hp and 3 hp models are single phase The crankcase heater is automatically energized when the main power 15 applied It should be on for at least 24 hours before startup to force dissolved refrigerant from the compressor oil 2 40 HP Portable Chillers Chapter 3 Installation 28 of 78 Chapter 4 Operation 4 1 Panel Buttons Indicator Lights and Switches Microprocessor Controllers Standard chillers use a microprocessor based PID controller These controllers are modular self contained units that can slide from their mounting housing They are factory set and adjusted no field adjustment to the internal controls are necessary Their standard operation range 15 30 F to 65 F 1 C to 18 See Figure 7 Typical Portable Chiller Microprocessor Controller ESCK Controller Indicator Name Description PV Process Value LED During normal operation the large red PV LED S on the controller displays the actual process US temperature at the To Process thermocouple It also lists parameter symbols during setup and error messages if an error occurs SV Set Value LED Durin
14. 50 F 10 C leaving water temperature at 2 4 gpm per ton 9 1 Ipm per 3 517 kW with 95 F 35 C ambient air For 50 Hz applications multiply capacity by 0 83 Nominal 60 Hz capacity flow rate must be maintained Nominal cooling Nom Com Refrigeration Power in amps capacity tons water pres Nom connections 460 3 60 in diaODS 1 2pumps Pes f os 94 zs wo 20 ru Se 2251182 242 199 Based on 50 F 10 C chilled water supply temperature and 95 F 35 C ambient air Optional additional process pump hp reduces chiller capacity by 0 2 tons per hp 0 703 kW ref cap per 0 746 kW pump power Based on 2 4 gpm per ton 9 1 3 517 kW nominal 1 pump optional oversized process pump adds to the total rated or running chiller amperage To find the new total chiller amperage subtract the standard process pump amperage from the optional pump amperage see Figure 1 on page 16 and add it to the chiller rated or running amperage Multiply 460 3 60 amperage by 2 0 for 208 230 3 60 amperages multiply by 0 8 for 575 3 60 amperages MOUNTING DETAILS 546 69 28 I 2 25 71 606 RAILS FEET d 34 RESERVOIR VENT I AUTOWATER MAKE UP SUPPLY OPTIONAL REFRIGERATION T OPTICS PRESSURE GUAGE DISCHARGE UNE PROCESS PRESSURE GUAGE OPTICS PROCESS SUPPLY TOP VIEW RESERVOIR FILL OPTIONAL 3
15. 6 Troubleshooting Check main disconnect fuses wiring and power lead to unit Voltage must be within plus or minus Wrong voltage supplied to unit Y0 nameplate taling Defective on off switch Replace Replace control circuit fuse Control circuit fuse blown Check transformer Check for a short circuit Defective control transformer Add water or water glycol solution as required High Low thermostat set higher Lower thermostat stage 1 set to 10 F than temperature of liquid in 6 C below the leaving temperature system you want Defective High Low thermostat Low refrigerant indicator on Check refrigerant charge Sight glass should be clear and the moisture indicator should be green while compressor is running Bubbles or foaming is normal when the hot gas by pass solenoid is energized Call for service if bubbling is occurring and or moisture indicator is yellow Check condenser fans for proper rotation xn Check for dirty condenser Bn He u Defective fan cycling control Defective fan motor Repair or replace Allow time to cool and reset then check for high low volt age It must be within Compressor internal overload or plus or minus 1096 of the nameplate fuses are open rating Check for open fuses and loose compressor electrical connections Repair or replace open Defective pump motor to Repair replace compressor auxiliary contact Broken wire in the compressor
16. 60 amperages ar 546 95 28 VIEW RESERVOIR VENT TO PROCESS AUTOWATER N REFRIGERATION MAKE UP SUPPLY OPTIONAL N E PROCESS PRESSURE GUAGE REFRIGERATION RESERVOIR FILL N DISCHARGE LINE 34 68 E 34 43 43 25 BYPASS FILTER T I OPTIONAL BYPASS FILTER FLOW METER LEFT SIDE VIEW FRONT VIEW OPTIONAL CONTROLLER WITH GRAPHIC PANEL ELECTRICAL ENCLOSURE AUDIBLE amp VISUAL ALARM OPTIONAL L PT gt ist II RESERVOIR _ SIGHT GLASS RESERVOIR DRAIN FROM PROCESS REAR VIEW Remote air cooled portable chillers come standard with mounting rails Remote air cooled portable chillers are charged with 25 psi 172 4 kPa 1 72 bars nitrogen for shipping purposes Com Process connections in NPT Dimensions Weights pressor 1 pump 2 Pump pump 1 pump in inches Ship 2 Oper to from to from no tank tank to from height width depth Ibs Ibs Ibs i 8 2513 20 30 2 15 23 aera 20 213 2337 340 1007 1607 1857 2273 2 5 3 2 5 3 2 5 3 43 3 34 0 100 7 2 235 2 462 2 901 2 5 3 2 5 3 2 5713 43 3 34 0 100 7 2 243 2 470 2 909 convert to multiply by 2 54 Add to height dimension based mounting options Weight is for sta
17. Leaving Water Temperature Discharge Line Size O D Eqiv 5hp 7 5 hp 10 hp 15 hp 20 hp 25 hp 30 hp 35 hp 40 hp 25 7 8 11 8 11 8 13 8 13 8 15 8 15 8 15 8 21 8 50 7 8 11 8 118 13 8 13 8 1 5 8 1 5 8 1 5 8 2 1 8 75 7 8 118 118 13 8 13 8 15 8 15 8 15 8 21 8 100 7 8 11 8 11 8 3 8 13 8 15 8 15 8 15 8 21 8 125 7 8 11 8 118 3 8 1 3 8 1 5 8 1 5 8 21 8 21 8 150 7 8 11 8 11 8 3 8 15 8 15 8 21 8 21 8 21 8 175 11 8 11 8 11 8 3 8 1 5 8 1 5 8 2 1 8 21 8 21 8 200 11 8 11 8 13 8 3 8 15 8 15 8 21 8 21 8 21 8 225 11 8 11 8 13 8 5 8 15 8 21 8 21 8 21 8 21 8 250 118 118 13 8 5 8 1 5 8 2 1 8 2 1 8 21 8 21 8 275 11 8 11 8 13 8 5 8 15 8 21 8 21 8 21 8 21 8 300 11 8 11 8 13 8 5 8 15 8 21 8 21 8 21 8 21 8 2 40 HP Portable Chillers Chapter 3 Installation 22 of 78 Refrigerant Charge Determination approximate amount of refrigerant charge required by the system varies based on the total length of the refrigerant lines and the size of the chiller Referring to Figure 5 determine the amount of charge based on the horsepower of the chiller and the amount of charge based on discharge and liquid line sizes and lengths Add these three numbers together to find the final operating charge The final operating charge must be verified by running the system and checking the liquid line sight glass Figure 5 Charge Determination Chiller Condenser Charge Field Installed Piping Charge Horsepower Lbs of Pi
18. Multiply Ibs by 0 454 to calculate Kg Operating weight is with a full 40 gallon 151 liter reservoir tank of water 2 40 HP Portable Chillers Chapter 7 Appendix 47 of 78 20 hp 25 hp and 30 hp Air Cooled Portable Chillers Nominal operating parameters for air cooled models are 50 F 10 C leaving water temperature at 2 4 per ton 9 1 per 3 517 kW with 95 F 35 C ambient air 50 Hz applications multiply capacity by 0 83 Nominal 60 Hz capacity flow rate must be maintained ower in amps 9 460 3 60 Discharge air 1 25 x 18 5 10 20 25 x 18 5 13 300 62 1 Based 50 10 chilled water supply temperature and 95 35 ambient air Optional additional process pump hp reduces chiller capacity by 0 2 tons per hp 0 703 kW ref cap per 0 746 kW pump power Based on 2 4 gpm per ton 9 1 Ipm per 3 517 kW nominal 1 pump An optional oversized process pump adds to the total rated or running chiller amperage To find the new total chiller amperage subtract the standard process pump amperage from the optional pump amperage see Figure 1 on page 16 and add it to the chiller rated or running amperage Multiply 460 3 60 amperage by 2 0 for 208 230 3 60 amperages multiply by 0 8 for 575 3 60 amperages To convert cfm to cmh multiply by 1 699
19. a pump lights whenever the pump s operates 4 High Discharge Temperature Light The High Discharge Temperature light comes on if the compressor discharge line temperature switch opens This switch prevents possible compressor failure due to over loading the compressor stops but the pump s continue to run This occurs when the discharge line temperature rises above 260 F 127 C Call a qualified refrigeration service technician or contact the Service Department Pump Overload Light The Pump Overload light installed on chillers with a pump s lights whenever a pump motor s has shut down from a motor overload condition High Refrigerant Pressure Light The High Refrigerant Pressure light comes on if the compressor discharge pressure exceeds the limit of the high pressure cutout switch The compressor stops but the pump s continue to run until you manually reset the high pressure cutout switch Call a qualified refrigeration service technician or contact the Service Department 2 40 HP Portable Chillers Chapter 4 Operation 32 of 78 dE Indicator Name Description Low Water The Low Water Flow Pressure light comes on when Flow Pressure the flow switch pressure switch on 2 amp 3 hp Light models senses that the water glycol flow rate through the evaporator has dropped below an acceptable level The flow switch opens shutting down the pump s and the chiller
20. and supply switch or dry contact interlock connected in series between these two terminals Refer to the schematic inside the control enclosure door 2 40 HP Portable Chillers Chapter 2 Functional Description 13 of 78 2 5 Optional Features Options marked with 4 indicate options that can be factory installed or retrofitted in the field Automatic Water Make Up Not available on chillers less reservoir tank Includes pressure regulating valve set at 3 to 5 psi an electric water solenoid valve a float switch mounted in the reservoir tank and the necessary internal piping to connect the chiller to a make up water source See Appendix for typical piping diagrams Caution Customer piping must provide backflow protection and venting of tank to atmosphere to prevent over pressurization of the reservoir tank See Central and Gravity Return Piping with Standpipe Diagram on page 64 Process Water Sidestream Filter Not available on chillers less pump and reservoir tank Includes a 50 micron filter flow meter ball valve for throttling water flow and the necessary piping to provide constant filtering of the process water at about one gallon per minute 1 gpm 3 8lpm General Fault Indicator Audible Alarm Includes an 85 dB 2 ft audible alarm buzzer and silence button with provisions for customer wiring indication interlock The alarm signals anytime that a fault is recognized during the operation of the chiller General Fault
21. casters or rails and can then be moved into position 5 Temporary hardware has been installed to prevent side panels from shifting in transit Remove hardware 6 Retain the crating material for reshipping the chiller in case hidden shipping damage is found Caution Never remove the unit from the front electrical control end or the rear pipe connection end Damage may result Electrical Connections Supply electricity of the voltage phase and cycle listed on the serial tag Total running amps are also found in the specification tables on pages 45 57 in the Appendix Bring properly sized power leads and ground from a fused disconnect installed by your electrician to the unit Use dual element fuses in the disconnect switch sized according to the National Electrical Code recommendations Note the outline drawings for egress into the cabinet Make sure all electrical connections are tight Typical wiring schematics are located on pages 70 78 in the Appendix Warning Make sure that electrical connections comply with all applicable electrical codes Ground the chiller in accordance with NEC Article 250 Operation voltage must be within plus or minus 10 of the nameplate rating Phase imbalance must be below 10 2 40 HP Portable Chillers Chapter 3 Installation 17 of 78 3 3 Process Water Connections All of our portable chillers have two chilled water connections The chilled water supply labeled To Process is the outlet for
22. equipment at a lower condenser entering air temperature can cause the chiller to lose capacity For entering air temperatures below 60 F an optional fan motor speed control is available We recommend maintaining a minimum 60 F ambient temperature 2 40 HP Portable Chillers Chapter 3 Installation 19 of 78 Remote Air Cooled Chiller Condensers Remote air cooled portable chillers are shipped with nitrogen holding charge and a full charge of oil excluding the amount needed for field piping The remote air condenser is shipped with a dry air charge Verify that the holding charge has not been lost prior to installation If there is no pressure leak test the unit and repair before installing the interconnecting refrigerant piping Read this entire section before installation Note Piping should be type L or type K refrigerant grade copper tubing only Proper sizing and installation has a significant effect on system performance reliability and safety Interconnecting Refrigerant Piping The chiller and condenser refrigerant lines are terminated with a cap and brazed closed Use a tube cutter to remove caps Caution Do not use a saw to remove the end caps because this will allow copper chips to contaminate the system A certified refrigeration contractor need only to install the interconnecting refrigerant piping between the chiller and the outdoor air cooled condenser This piping must be properly sized type L or type
23. hp and 3 1 2 hp models 4 swivel casters on 5 hp to 15 hp models and 5 swivel casters with brake on 20 hp to 40 hp models e Valved process water connections e Pressure actuated process water bypass valve for system protection only on single pump models only To process 2 1 2 dual scale liquid filled water pressure gauge e Fully insulated refrigeration and process water piping e Isolated fan section on air cooled models allowing chiller to run during maintenance e 20 mesh Y strainer on process water piping into the evaporator 2 40 HP Portable Chillers Chapter 2 Functional Description 10 of 78 Electrical Features Fully accessible NEMA 12 style electrical control enclosure Single point power and ground connection Non fused disconnect switch lockable Branch circuit fusing 208 230 3 60 and 460 3 60 volt consult factory for other voltages 208 230 1 60 volt on 2 and 3 1 2 hp models Refrigeration Features R 22 refrigerant Hot gas bypass capacity control High discharge temperature cutout on 2 hp to 30 hp models High and low refrigerant pressure cutout switches Fan cycling switch 5 hp to 30 hp air cooled models only High pressure spring actuated relief valve Multiple refrigeration access ports Compressor service valves Hot gas bypass and liquid line shut off ball valves on 5 hp to 40 hp models Filter dryer Sight glass Balanced port thermal expansion valve Controller Features Off the shelf micropro
24. the chilled water leading to the process being cooled The chilled water return labeled From Process is the inlet leading from the process back into the chiller to be cooled and re circulated All external chilled water connections should be run full size to the process Flow and pressure information is available on pages 58 61 in the Appendix The largest possible openings and passages should be provided for the flow of chilled water through platens dies molds or other pieces of equipment Note Be sure to reduce external pressure drop as much as possible by generously sizing piping and tooling water passageways 3 4 Bypass Valve Considerations Our portable chillers have a spring loaded bypass valve If the chilled water shut off valves are inadvertently closed while the chiller is running the factory set bypass valve opens and allows a small amount of water to flow through the chiller This action protects the chiller from freeze up and allows the other cutout devices to shut down the chiller The bypass valve is not intended to provide continuous full bypass flow Caution Do not attempt to adjust or otherwise tamper with the bypass valve Your warranty will be voided 3 5 Galvanic Corrosion Considerations The materials used in the water circuit piping of these chillers are non ferrous and react electro chemically with ferrous metallic materials Some water has dissolved minerals that greatly accelerate the reaction between dissimi
25. to use Remote air cooled chillers require field installation by qualified technicians Standard range of operation is 30 F to 65 F 1 C to 18 C for applications using a water glycol mix and 45 F to 65 F 7 to 18 C for water only applications A factory installed crankcase pressure regulating valve option is available for processes requiring a leaving water temperature of up to 75 F 24 C Chilled Water Circuit Cooling water To Process and From Process connections are made at the gate valves provided outside the unit Warm coolant water and glycol mixture returns from the process and goes into the reservoir tank The coolant is then pumped through the evaporator where it is cooled The coolant flows to the process and returns to repeat the cycle A pressure actuated process water bypass valve located between the supply line and reservoir tank single pump models only allows minimal flow through the unit during the intermittent fluctuating flow conditions It is not intended to provide continuous full bypass flow This minimal flow allows the temperature sensor to signal the controller to shut down the compressor because of the drop in process water temperature Typically the flow switch shuts down the chiller in this low flow condition The 2 hp and 3 1 2 hp models have a 1 4 poly tubing constant bypass to provide additional process water bypass to prevent system freeze up Refrigeration Circuit
26. total distance between the chiller and condenser must not exceed 200 feet or 300 equivalent pipe feet e Discharge line risers cannot exceed an elevation difference greater than 100 feet without a 2 efficiency decrease e Refer to page 62 of the Appendix for the location of traps e Refrigeration lines must not be crossed i e chiller liquid lines are to be piped to condenser liquid lines Sizing Refrigerant Lines To determine field installed liquid and discharge line sizes first establish the equivalent length of pipe for each line valve and elbow Chiller capacity and leaving water temperature range is also required See Figure 2 on page 22 for lengths of refrigerant valves and fittings Liquid Line Sizing The liquid line should be sized as small as possible while maintaining acceptable pressure drop to minimize the refrigerant charge Liquid line risers must not exceed 15 feet from the base of the air cooled condenser Horizontal runs do not require a pitch Insulation is not required unless the line is installed in a high ambient area i e boiler room Install a liquid line charging valve to facilitate refrigerant charging See Figure 3 on page 22 for sizing information See Figure 5 on page 23 for charge determination Discharge Line Sizing For horizontal runs the discharge line should be pitched downward in the direction of flow at a rate of 1 2 for every 10 feet This will allow oil to flow towards the condenser Discharg
27. 2 4 gpm per ton 9 1 Ipm per 3 517 kW with 95 F 35 C ambient air For 50 Hz applications multiply capacity by 0 83 Nominal 60 Hz capacity flow rate must be maintained Nominal cooling Nom Com Refrigeration Power in amps capacity O tons water pres connections 460 3 60 hp flow sor dia 005 1pump 2 O hp Discharge Liquid rated running rated 20 19 4 18 4 18 0 46 5 2 9 10 5 13 8 Te 43 9 37 6 47 0 40 7 25 23 8 22 8 22 4 572 2 13 5 13 8 55 9 42 1 59 0 45 2 30 29 2 28 2 27 8 70 2 2 15 5 13 8 60 0 50 4 63 2 53 5 35 30 6 29 1 28 7 73 5 35 7 5 15 8 11 8 64 4 60 3 67 5 63 4 40 36 9 35 4 35 0 88 6 40 7 5 15 3 11 3 81 9 68 8 85 0 58 0 Based 50 F 10 C chilled water supply temperature and 95 F 35 C ambient Optional additional process pump reduces capacity by 0 2 tons 0 703 kW ref 0 746 kW pump power Based on 2 4 gpm per ton 9 1 Ipm per 3 517 kW nominal 1 pump An optional oversized process pump adds to the total rated or running chiller amperage To find the new total chiller amperage subtract the standard process pump amperage from the optional pump amperage see Figure 1 on page 16 and add it to the chiller rated or running amperage Multiply 460 3 60 amperage by 2 0 for 208 230 3 60 amperages multiply by 0 8 for 575 3
28. 2 40 hp Portable Chillers Part Number A0554832 Bulletin Number SC2 610C 8 Effective 11 01 03 Write Down Your Serial Numbers Here For Future Reference We are committed to a continuing program of product improvement Specifications appearance and dimensions described in this manual are subject to change without notice DCN No Copyright 2004 All rights reserved Shipping Information Unpacking and Inspection You should inspect your equipment for possible shipping damage Thoroughly check the equipment for any damage that might have occurred in transit such as broken or loose wiring and components loose hardware and mounting screws etc In the Event of Shipping Damage According to the contract terms and conditions of the Carrier the responsibility of the Shipper ends at the time and place of shipment Notify the transportation company s local agent if you discover damage Hold the damaged goods and packing material for the examining agent s inspection Do not return any goods before the transportation company s inspection and authorization File a claim with the transportation company Substantiate the claim by referring to the agent s report A certified copy of our invoice 15 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 Advise customer service regarding your wish for assistance and to obta
29. 4 d OPTICS PROCESS RETURN OPTIONAL 1 9 Wi E N TI CONTROLLER WITH o B zi GRAPHIC PANEL 8 s 7 ELECTRICAL EAM 1 38 63 ENCLOSURE 34 68 gd 3443 n 3018 T 2843 AUDIBLE amp VISUAL ALARM 24 18 4 OPTIONAL 16 75 4 4 1075 j B B 425 j NN _ AV BYPASS FILTER LEFT SIDE VIEW Front view 1 RESERVOIR N oie SIGHT GLASS 225 1346 2 BYPASS FILTER FLOW METER RESERVOIR DRAIN 1952 OPTIONAL 20 10 FROM PROCESS REAR VIEW Remote air cooled portable chillers come standard with mounting rails Remote air cooled portable chillers are charged with 25 psi 172 4 kPa 1 72 bars nitrogen for shipping purposes Com Process connections in NPT Dimensions Weighs pressor no pump 1 pump no in inches Ship Oper hp no tank tank to from height width Depth Ibs lbs lbs 1 5 2 0 1052 1 159 2 0 3 0 1095 1 202 convert to multiply by 2 54 Add to height dimension based mounting options Weight is for standard chiller Some optional features will increase weight Operating weight is with a full 40 gallon 151 liter reservoir tank of water 2 40 HP Portable Chillers Chapter 7 Appendix 55 of 78 20 hp through 40 Remote Air Cooled Portable Chillers Nominal operating parameters for remote air cooled models are 50 F 10 C leaving water temperature at
30. Appendix 52 of 78 35 hp 40 Water Cooled Portable Chillers Nominal operating parameters for water cooled models 50 F 10 C leaving water temperature at 2 4 per ton 9 1 Ipm per 3 517 kW with 85 F 29 C tower water For 50 Hz applications multiply capacity by 0 83 Nominal 60 Hz capacity flow rate must be maintained Nominal cooling NominallCom Power in amps water pres 460 3 60 flow City Tas s 11 he he ater water frated rated running rated running Based on 50 F 10 C chilled water Supply 855 29 C ower water Optional additional process pump hp reduces chiller capacity by 0 2 tons per hp 0 703 kW ref cap per 0 746 kW pump power Based on 2 4 gpm per ton 9 1 3 517 kW nominal 1 pump Based on availability of 85 F 29 C tower water at 25 psi 172 4 kPa 1 7 bars minimum Based on availability of 70 F 21 C city water at 25 psi 172 4 kPa 1 7 bars minimum An optional oversized process pump adds to the total rated or running chiller amperage To find the new total chiller amperage subtract the standard process pump amperage from the optional pump amperage see Figure 1 on page 16 and add it to the chiller rated or running amperage Multiply 460 3 60 amperage by 2 0 for 208 230 3 60 amperages 34 I CONDENSER WATER OUT ir COND
31. Chillers Chapter 4 Operation 30 of 78 Figure 7 Typical Portable Chiller Microprocessor Controllers outs MANU ATE ma 5 2 40 HP Portable Chillers Chapter 4 Operation 31 of 78 Graphic Panel See Figure 8 on Page 32 Indicator Name Description OQ Compressor On Light The Compressor On light turns on whenever the compressor 15 operating 4 Low Temperature Light The Low Temperature light comes on if the process water glycol temperature drops below the High Low thermostat set point The High Low thermostat stage one switch opens the control circuit shutting down the compressor but the process water glycol pump s continue to operate This action prevents possible chiller evaporator freeze up Hot Gas Light The Hot Gas By Pass light turns on when the hot gas bypass valve is in operation The LED the controller also lights when the hot gas bypass valve 15 in operation O 4 High Temperature Light The High Temperature light comes on if the process water glycol temperature rises above the High Low thermostat stage two set point The High Low thermostat stage two switch opens the control circuit shutting down the process water glycol pump s and the chiller shuts off This action prevents possible system failure from overheating of the process water glycol OC Pump On Light The Pump On light installed on chillers with
32. ENSER WATER IN 7 RESERVOIR VENT VIEW AUTO WATER 1700 95 26 MAKE UP SUPPLY OPTIONAB 46 M TO PROCESS PROCESS PRESSURE GAUGE RESERVORFLL 4 ELECTRICAL ENCLOSURE 4531 194 i 425 lt N Vr 1 BYPASS FILTER RESERVOIR SIGHT GLASS OPTIONAL lt 1346 S BYPASS FILTER FLOW METER LEFT SIDE VIEW RESERVOIR DRAIN OPTIONAL CONTROLLER 1571 WITH GRAPHIC PANEL Uum T FRONTVEW N AUDIBLE amp VISUAL 25 19 53 FROM PROCESS ALARM 2010 REAR VIEW REAR VIEW 35 hp and 40 hp water cooled chillers come standard with 4 101 mm swivel casters OPTIONAL Process connections Dimensions 1 pump 2 Pump pump 1 pump Ship Oper to from to from tank tank 2 669 2 919 2 5713 100 7 2 680 2 930 3 369 to cm a 2 54 to height diens based on mounting options Weight is for standard chiller Some optional features will increase weight Multiply by 0 454 to calculate Kg Operating weight is with a full 80 gallon 303 liter reservoir tank of water 2 40 HP Portable Chillers Chapter 7 Appendix 53 of 78 5 and 7 5 Remote Air Cooled Portable C
33. IN EN Note Pressure is proportional to flow Recirculation pump is required for values exceeding those listed Recirculation Pump Specifications 0 2384 90 620 30 35 40 2 40 HP Portable Chillers Chapter 7 Appendix 61 of 78 7 5 Remote Air Cooled Chiller Configurations Configuration A EC Liquid line riser should not exceed 15 feet from base of air cooled condenser Configuration B AEE HE 2 40 HP Portable Chillers Chapter 7 Appendix 62 of 78 7 6 Typical Ductwork for Air Cooled Chillers N BIRD 5 DAMPER 9 Ly 2 FLASHING 55 55 lt lt lt NS S S S S S S S SONY OPPOSED DOUBLE DAMPERS lt DEFLECTION NN amp LINKAGE GRILLE BACKDRAFT AUN lt DAMPER 7 Z gt ML 2 A SS E 7 lt A TARN 4 Z 74 Y N S Z 7 R V N NUN BS N N lt OPPOSED N OPPOSED N NON DAMPERS X N DAMPERS BIRD SCREEN XN amp LINKAGE amp LINKAGE ns NON N BS b aS 7 KA FLEXBLE FLEXIBLE XN QN CONNECTIONS CONNECTIONS NON MON ALL UNITS ALL UNITS e N N bw SN NON NX N AIR IN AIRIN Pi
34. ING this equipment this equipment within design specifications and LOCK ALL DISCONNECTS before working on equipment You should remove the fuses and carry them with you sure the equipment and components are properly GROUNDED before you switch on power M When welding or brazing in or around this equipment make 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 Refrigeration systems can develop refrigerant pressures in excess of 500 psi 3 447 5 34 47 bars DO NOT CUT INTO THE REFRIGERATION SYSTEM This must be performed by a qualified service technician only Do not restore power until you remove all tools test equipment etc and the equipment and related components are fully reassembled Only PROPERLY TRAINED personnel familiar with the information in this manual should work on this equipment We have long recognized the importance of safety and have designed and manufactured our equipment with operator safety as a prime consideration We expect you as a user to abide by the foregoing recommendations in order to make operator safety a reality 1 3 Responsibility These machines are constructed for maximum operator safety when used under standard operating conditions and when recommended instructions are followed in t
35. Indicator Audible Visual Alarm Includes a 100 dB 10 ft audible alarm horn 108 000 peak candlepower 80 flash min visual alarm strobe and silence button with provisions for customer wiring indication interlock The alarm signals anytime that a fault is recognized during the operation of the chiller Compressor Hour Meter Includes a DIN mount hour meter that keeps track of the total time that the compressor runs Communications Options RS 232C and RS 485 communications standards are available Recirculation Pump Necessary whenever process water flow 15 less than 2 2 per ton 8 3 Ipm per 3 517 kW or greater than 4 8 gpm per ton 18 2 Ipm per 3 517 kW High Pressure Fans Provides for an additional 0 30 WC 75 pa of static pressure on fan discharge High pressure fans are necessary and must be included in chiller installations where exiting air exhausts through ductwork The fans are available on 5 to 15 hp air cooled chillers They can be retrofitted without sheet metal modification but will require changing out fan blades and in some cases fan motors and electrical components 20 hp to 30 hp models come standard with squirrel cage blowers which can be ducted Variable Speed Fan Available on 5 to 15 hp air cooled chillers Reduces the speed of the fan based on entering air temperature and system load allowing the chiller to operate in ambient temperatures below 60 F 15 5 C This option will also reduce fan noise in ambi
36. N 1 WALL N N cH cou iS Tu X NN NON LN N o o Ps _ NON N NJ 3 J NN N NON 30 00 S ON m SN 4 MIN N MON ON X NN US N o N EN SY T CN 1 0554829 SJ See specification tables on pages 45 48 for air flow and pressure capacities When locating your air cooled portable chiller and designing its ductwork note any potential high temperature conditions when discharging into your building and any negative pressures with the building when discharging air outside Notes Customer use of ductwork requires the high pressure fan option for models 5 through 15 hp Allow 30 77 cm minimum clearance around the chiller footprint to facilitate free passage of cooling air and service accessibility Size the ductwork for maximum capacity Support ductwork from the building structure not off of the chiller Back draft damper to outside must be closed at all times when fan blower is not operating Chillers with dual fans blower must have a back draft damper on the cycling fan blower to prevent recirculation of hot discharge air Chillers are designed to operate at a condensing entering air temperature of 60 F 16 C minimum e Maximum total static pressure drop external to the chiller must not exceed 0 30 WG 75 pa 2 40 HP Portable Chillers Chapter 7 Appendix 63 of 78 7 7 Piping Diagrams Central and Gra
37. Normal R 22 refrigerant condensing pressure is 210 psi with 85 F 27 C water at 25 psi entering condenser water pressure Condenser Water Out Condenser water return labeled Condenser Water Out is located at the rear of the chiller It 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 A water regulating valve is a standard feature in the condenser water return line Air Cooled Chiller Condensers Air cooled 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 air cooled chillers in locations where steam hot air or fume exhausts can be drawn into the chiller A typical ductwork diagram is located on page 63 in the Appendix of this manual Caution Clean air cooled condensers and filters frequently Failure to do so results in reduced capacity increased operating costs and possible failure of the equipment Cleaning instructions can be found on page 38 in the Maintenance chapter of this manual Normal maximum refrigerant condensing pressure with 95 F 35 C air entering the condenser is 260 psi Condensing Air Temperature Our air cooled portable chillers are designed to operate at a minimum condenser entering air temperature of approximately 60 F 15 5 C Operation of the
38. R 5 CASTER RAILS FEET MOUNTING DETAILS z T RESERVOIR VENT ATER MAKE UP SUPPLY OPTIONAL N N TO PROCESS OPTICS PRESSURE GAUGE NN CONDENSER WATER OUT Y OPTIONAL N N N PROCESS PRESSURE GAUGE N RESERVOIR FILL 84 CONDENSER WATER IN I VIEW OPTICS PROCESS SUPPLY OPTIONAL OPTICS PROCESS RETURN 1 Fi OPTIONAL gl i g P N 11 1 Fi ELECTRICAL 3 24 38 63 a ENCLOSURE 29 24 36 d 1 28 11 N 16 75 N 10 75 isi qd gt SE 2 ay WK BYPASS FILTER SEE MOUNTING DETAILS Wy LEFT SIDE VIEW ave roy FRONT VIEW OPTIONAL CONTROLLER WITH 12 BYPASS FILTER FLOW METER GRAPHIC PANEL RESERVOIR _ SIGHT GLASS RESERVOIR DRAIN OPTIONAL AUDIBLE amp VISUAL ALARM 4 93 OPTIONAL 8 40 FROM PROCESS REAR VIEW 10 hp and 15 hp water cooled chillers come standard with 4 101 mm swivel casters Process connections NPT Dimensions Weights 1 pump in inches 5 Oper no tank tank to from To convert to cm multiply by 2 54 Add to height dimension based on mounting options Weight is for standard chiller Some optional features will increase weight Multiply by 0 454 to calculate Kg Operating weight is with a full 40 gallon 151 liter reservoir tank of water 2 40 HP Portab
39. STER RAILS FEET OPTICS PRESSURE GUAGE OPTIONAL PROCESS PRESSURE GUAGE RESERVOIR FILL 9 4 D RESERVOIR VENT AUTOWATER MAKE UP SUPPLY OPTIONAL TO PROCESS BYPASS FILTER 2598 OPTIONAL OPTICS PROCESS SUPPLY OPTIONAL AIR IN gt lt AIR IN 5 E id puru e S j PATE CONTROLLER WITH GRAPHIC PANEL ELECTRICAL ENCLOSURE 5 OPTICS PROCESS RETURN OPTIONAL d 34 68 30 18 2418 4 25 RESERVOIR SIGHT GLASS 4 RESERVOIR DRAIN 7 AUDIBLE amp VISUAL ALARM OPTIONAL 16 75 10 75 A y SEFMOUNTNGDETALS 71 7 LEFT SIDE VIEW 777 80554819 FRONTVEW Y BYPASS FILTER FLOW gt OPTIONAL FROM PROCESS 19 52 20 10 REAR VIEW 10 hp and 15 hp air cooled chillers come standard with 4 101 mm swivel casters Com Process connections in NPT Dimensions oye eser dd pressor umo pumps 1 pump no in inches Oper no tank tank Ibs Ibs en ld 1 5 3 0 1 5 2 0 150 2 0 3 0 2 0 3 0 To convert to cm multiply by 2 54 Add to height dimension based on mounting options Weight is for standard chiller Some optional features will increase weight
40. She Locate and repair control circuit Pump runs compressor cycles at Incorrect High Low Thermostat Lower set point to 10 F 6 C below short intervals setting desired leaving water temperature No power Unit does not run Piping flow switch circuit open Refrigerant low pressure switch contacts open Refrigerant high pressure indicator 2 40 HP Portable Chillers Chapter 6 Troubleshooting 41 of 78 sure that the water glycol mixture protection is right for the process for process Defective or improperly set Water temperature is too high High Low thermostat J Pa e Refrigerant Oe Call service to adjust pressure control set too high Call service to find and repair the leak then have refrigerant added Verify rotation if running in reverse Pump pressure low refer to curves rotation reverse any two main power for normal pressure for various leads Re verify for correct pump pumps rotation Check for partially closed valves etc Pump pressure is too high Restricted water flow Make sure that all lines are properly sized Restricted condenser air Clean filters Po Cean condenser Unit runs continuously but not Unit low on refrigerant Check the refrigerant charge h cooli i i enough power Compressor not operating Call service efficiently Unit under sized for application Call sales rep Refrigerant charge is low Pump running i
41. TING 41 CHAPTER 7 APPENDIX 43 T A Warrantiy E 43 7 2 Technical anasu 44 Parts 44 Service Departmenit 44 n e 44 Contract Department end n 44 7 5 Drawings and Specifications a 45 2 hp and 3 1 2 hp Air Cooled Portable Chillers 45 5 hp and 7 5 hp Air Cooled Portable Chillers 46 10 hp and 15 hp Air Cooled Portable Chillers 47 20 hp 25 hp and 30 hp Air Cooled Portable Chillers 48 2 hp and 3 5 hp Water Cooled Portable Chillers 49 5 hp and 7 5 hp Water Cooled Portable Chillers 50 10 hp and 15 hp Water Cooled Portable 51 20 hp 25 hp and 30 hp Water Cooled Portable Chillers 52 35 hp and 40 hp Water Cooled Portable Chillers 53 5 hp a
42. TIONAL OPTICS PRESSURE GAUGE BYPASS FILTER FLOW METER OPTIONAL PROCESS TOP VIEW CONTROLLER WITH GRAPHIC PANEL PROCESS PRESSURE GAUGE REFHIGEBATION RESERVOIR FILL PRAD HNE REFRIGERATION 7 DISCHARGE LINE i lt gt 3 3 C y g sd I e Aw ij 3863 ELECTRICAL BO 34 43 5 7 ENCLOSURE 28 43 TaS r 56 FILTER LEFT SIDE VIEW 0564820 FRONT VIEW RESERVOIR SIGHT GLASS A N OPTIONAL 35 1 RESERVOIR DRAIN 77 Nom 0488 AUDIBLE amp VISUAL ALARM FROM PROCESS OPTIONAL REAR VIEW Remote air cooled portable chillers come standard with mounting rails Remote air cooled portable chillers are charged with 25 psi 172 4 kPa 1 72 bars nitrogen for shipping purposes Com Process connections in NPT Dimensions Weights pressor 1 inches tank tank to from w s 2 0 1 5 5 0 1 5 1 5 2 0 40 9 34 0 54 7 597 748 930 1 57 2 0 convert to multiply by 2 54 Add to height dimension based mounting options Weight is for standard chiller Some optional features will increase weight Operating weight is with a full 20 gallon 76 liter reservoir tank of water 2 40 HP Portable Chillers Chapter 7 Appendix 54 of 78 10 hp and 15 hp Remote Air Cooled Portable Chillers Nominal operating parameters for remote air cooled models are
43. _ AUTO WATER MEW MAKE UP SUPPLY OPTIONAL 55 PROCESS PRESSURE GAUGE CONDENSER WATER OUT RESERVOIR FILL i 9 4 NN 4 CONDENSER WATER IN El N olf c 1 ELECTRICAL 34 68 hom h ENCLOSURE 33 18 lt 31 74 30 18 25 74 4 27 18 2418 N r N B x j 2 sassa mL Im KA 6 68 RESERVOIR SIGHT GLASS 4 5 FRONT VIEW 13 46 BYPASS FILTER FLOW METER 1 LEFT SIDE VIEW CONTROLLER RESERVOIR DRAIN OPTIONAL WITH 1571 828 GRAPHIC PANEL AUDIBLE amp VISUAL ALARI 19 53 FROM PROCESS REAR VIEW OPTIONAL 2010 REAR VIEW 20 hp 25 hp and 30 hp water cooled chillers come standard with 4 101 mm swivel casters Process connections in NPT Dimensions Weights 2 Pump 1 in inches Ship 2 o from to from no tank tank to from To convert to cm multiply by 2 54 Add to height dimension based on mounting options Weight is for standard chiller Some optional features will increase weight Multiply by 0 454 to calculate Kg Operating weight is with a full 80 gallon 303 liter reservoir tank of water 2 40 HP Portable Chillers Chapter 7
44. able Chillers Chapter 7 Appendix 46 of 78 10 hp and 15 Air Cooled Portable Chillers Nominal operating parameters for air cooled models are 50 F 10 C leaving water temperature at 2 4 gpm per ton 9 1 Ipm per 3 517 kW with 95 F 35 C ambient air For 50 Hz applications multiply capacity by 0 83 Nominal 60 Hz capacity flow rate must be maintained Nominal cooling Power amps 460 3 60 capacity tons Discharge air 2pumps pump 1 pump 2 pump openings cfm rated running rated running 99 95 94 0 20027 10 000 Based 50 F 10 C chilled water supply temperature and 95 F 35 C ambient air Optional additional process pump hp reduces chiller capacity by 0 2 tons per hp 0 703 kW ref cap per 0 746 kW pump power Based on 2 4 gpm per ton 9 1 per 3 517 kW nominal 1 pump Customer use of ductwork requires optional high pressure fan for 5 hp to 15 hp 3 73 kW to 11 20 kW models An optional oversized process pump adds to the total rated or running chiller amperage To find the new total chiller amperage subtract the standard process pump amperage from the optional pump amperage see Figure 1 on page 16 and add it to the chiller rated or running amperage Multiply 460 3 60 amperage by 2 0 for 208 230 3 60 amperages multiply by 0 8 for 575 3 60 amperages To convert cfm to cmh multiply by 1 699 MOUNTING DETAILS m D J ese N d 2 1 n 4 CASTER 5 CA
45. al eventually causing bearing failure Refrigeration compressors are hermetically sealed and no lubrication is required 5 2 Filter Cleaning Air filter cleaning is important to keep your air cooled portable chiller operating at peak efficiency and capacity Clean the filters whenever they appear dirty or at regularly scheduled intervals 1 Turn the chiller off Slide the filter up off of the retaining pins holding it in place along its bottom 2 3 the bottom of the filter away from the chiller 4 Slide it down and out 5 Wash down the filter with clean water preferably with a garden hose directing the flow of water opposite the direction of airflow If dirt is heavy use a mild detergent and rinse well Allow the filter to dry completely before replacing it on the chiller Note Keep a spare air filter set on hand Install and use it while cleaning Caution Do not use compressed air to blow off a dirty filter It will not clean very well and the filter could be damaged Never run the chiller without properly installed filters 2 40 HP Portable Chillers Chapter 5 Maintenance 38 of 78 5 3 Maintaining the Condenser Dirty condenser heat exchange surfaces reduce system capacity and efficiency Air and Remote Air Cooled Chillers Brush or vacuum light dirt accumulations off the aluminum condenser fins Avoid bending or damaging them Heavy dirt accumulations on the fins may require professional cleaning Water Coo
46. ales representatives Contact our Sales Department for the name of the sales representative nearest you Contract Department Call 414 354 0970 Monday Friday 8am 5pm CST Let us install your system The Contract Department offers any or all of these services project planning System packages including drawings equipment labor and construction materials and union or non union installations 2 40 HP Portable Chillers Chapter 7 Appendix 44 of 78 7 3 Drawings Specifications 2 hp 3 1 2 hp Air Cooled Portable Chillers Nominal operating parameters for air cooled models are 50 F 10 C leaving water temperature at 2 4 gpm per ton 9 1 Ipm per 3 517 kW with 95 F 35 C ambient air For 50 Hz applications multiply capacity by 0 83 Nominal 60 Hz capacity flow rate must be maintained Power in amps 460 3 60 Nominal cooling Water Com capacity tons pressor pump Discharge air 1pump hp rated running 2 19 17 46 20 10 10185 1475 80 69 Based 50 F 10 C chilled water supply temperature and 95 F 35 C ambient air Optional additional process pump hp kW reduces chiller capacity by 0 2 tons per hp 0 703 kW ref cap per 0 746 kW pump power Based 2 4 per ton 9 1 3 517 kW nominal 1 pump An optional oversized process pump adds to the total rated
47. and tube evaporators are used on the 35 hp and 40 hp models Air Cooled Condenser Aluminum fin copper tube with washable filters package unit only Water Cooled Condenser 2 hp to 7 5 hp models use tube in tube condensers 10 hp to 40 hp use cleanable shell and tube condensers All come with cooling water regulating valves for cooling tower water or city water Remote Air Cooled Condenser 5 hp to 50 hp only Aluminum fin copper tube with low ambient control down to 20 F 29 C via pressure actuated fan staging and a variable speed primary fan Reservoir 2 hp and 3 1 2 hp models use 6 gallon polyethylene tank 5 hp and 7 5 hp models use 20 gallon polyethylene tank 10 hp and 15 hp models use a 40 gallon polyethylene tank 20 hp to 30 hp models use an 80 gallon polyethylene tank and 35 hp and 40 hp models use an 80 gallon stainless steel tank Piping Non ferrous piping for 2 hp through 30 hp models 35 hp and 40 hp models have ferrous piping Pump Non overloading ODP motors horizontally mounted stamped stainless steel or cast bronze construction Other Mechanical Features e External fill drain sight glass e Low process water pressure switch on 2 hp and 3 1 2 hp models e Low process water flow switch on 5 hp to 40 hp models Galvanized steel mounting rails for remote air cooled models NEMA rated fan motor s on air cooled models e Galvanized structural steel frame painted cabinetry with 2 1 2 swivel casters on 2
48. cessor based PID auto tuning controller with To Process and Set Point LED readout Microprocessor temperature switch with LCD display for process water freeze protection compressor cutout and high process water temperature pump cutout Electronic time delay for proof of water flow pressure models w pump only Off delay water flow timer to prevent short cycling models w pump only Low refrigerant pressure switch override timer for low ambient start up on remote air cooled and air cooled chillers with the variable speed fan option Graphic control panel with indicating and warning status lights Other Features One year labor warranty and one year compressor warranty Two year parts warranty 2 40 HP Portable Chillers Chapter 2 Functional Description 11 of 78 e Three year limited controller warranty 2 4 Safety Devices and Interlocks High Low Thermostat Control The high low thermostat is a cutout device that protects the chiller system in two ways Stage one of the thermostat shuts down the compressor if the chilled process water glycol temperature approaches the particular mixture s freezing point The chilled process water glycol pump will continue to run The high low thermostat stage one cutout temperature is factory set at 42 F 5 5 C This is correct for a supply water temperature of 50 F 10 C the rated capacity operating temperature If you want lower chilled water temperatures mix process water with glycol to pr
49. closure to 8 F 4 4 C below the To Process temperature you want The High Low thermostat 15 factory set at 42 F 6 C See page 36 for information on resetting the High Low thermostat 4 Check the pump amp draw and pump pressure Make sure that the amp draw reading is within the running load and service factor amps 5 Operate the chiller looking for any leaks and listening for unusual noises or vibrations that could indicate improper operation Note Elevated sound level and substantially reduced current draw indicate reverse rotation After several minutes of operation the compressor internal protector trips 4 3 Setting the Process Water Temperatures 5 Controller To change the process water temperature set point press the Up Arrow button to raise the set point and press the Down Arrow button to lower the set point Sterlco 2000 Controller To change the process water temperature set point press the Index key then press the Up Arrow button to raise the set point or the Down button to lower the set point Press the Enter key for the controller to accept the new values Press the Index key to return to the Home position 4 4 Auto Tuning ESCK Controller Only The Auto Tune function lets you fine tune the control PID to process requirements Activate the Auto Tune function whenever the process under control changes Don t be alarmed by control response It may take the process temperature above and below the set points as
50. dix 49 of 78 5 and 7 5 Water Cooled Portable Chillers Nominal operating parameters for water cooled models 50 F 10 C leaving water temperature at 2 4 per ton 9 1 Ipm per 3 517 kW with 85 F 29 C tower water For 50 Hz applications multiply capacity by 0 83 Nominal 60 Hz capacity flow rate must be maintained Nominal Com Power amps capacity tons 460 3 60 pump pump pump sor conn Tower City a rated running rated running ho jn water ster ofated bes Les io j pio 09 213 07 1 51327 Based on 50 F 10 C chilled water Supply temperature and 85 F 29 C ower water Optional additional process pump hp reduces chiller capacity by 0 2 tons per hp 0 703 kW ref cap per 0 746 kW pump power Based on 2 4 gpm per ton 9 1 Ipm per 3 517 kW nominal 1 pump Based on availability of 85 F 29 C tower water at 25 psi 172 4 kPa 1 7 bars minimum Based on availability of 70 F 21 C city water at 25 psi 172 4 kPa 1 7 bars minimum optional oversized process pump adds to the total rated or running chiller amperage To find the new total chiller amperage subtract the standard process pump amperage from the optional pump amperage see Figure 1 on page 16 and add it to the chiller rated or running amperage 460 3 60 p 2 0 for 208 230 3 60 amperages gt
51. e The oil pressure safety switch is a manual reset device Call a refrigeration service technician to analyze the problem and reset the control Fan Cycling Switch Air cooled models only 5 hp and 7 5 hp models have one fan The fan cycling switch turns on the fan when the discharge pressure in the condenser reaches 300 psi and turns it off when the pressure drops below 190 psi 10 hp to 30 hp models have two fans One fan runs continuously every time the compressor operates The second fan turns on when the discharge pressure in the condenser reaches 275 psi and turns off when the pressure drops below 200 psi Pressure Switch 2 hp and 3 1 2 hp models have a pressure switch cutout device mounted in the process piping The switch shuts down the chiller if it senses that the water glycol pressure through the evaporator has dropped below an acceptable level The pressure switch opens the control circuit shuts down the pumps and shuts off the chiller Flow Switch 5 hp to 40 hp models only The flow switch cutout device mounted in the process piping shuts down the chiller if senses that the water glycol flow rate through the evaporator has dropped below an acceptable level The flow switch opens the control circuit and shuts down the pumps and the chiller Remote Start Stop Interlock An additional contact is provided to allow the remote starting or stopping of the chiller To use this feature remove the jumper between terminals X1 and 1
52. e see Figure 1 on page 16 and add it to the chiller rated or running amperage Multiply 460 3 60 amperage by 2 0 for 208 230 3 60 amperages multiply by 0 8 for 575 3 60 amperages To convert cfm to cmh multiply by 1 699 546 49 28 1 DE LT 5 5884 6 56 va 6 06 N 1 2 i 4 CASTER 5 CASTER RAILS FEET MOUNTING DETAILS our OPTICS PROCESS SUPPLY OPTIONAL OPTICS PROCESS RETURN OPTIONAL N OPTICS PRESSURE GAUGE A EINS RESERVOIR VEN AIR IN AUTO WATER N PROCESS PRESSURE GAUGE MAKE UP SUPPLY OPTIONAL RESERVOIR FILL 94 L 1 TI 1 1 4 34 68 mh I ELECTRICAL 33 18 it de 2 Cum f ENCLOSURE 2595 I TO PROCESS 27 18 24 18 2 51 BYPASS FILTER FLOW METER VE OPTIONAL isin BYPASS FILTER do R iG 4 OPTIONAL SEE MOUNTING DETAILS LEFTSDEVEW 4 A0554819 Y FRONTVEW NQ RESERVOIR SIGHT GLASS FROM PROCESS i 13 46 RESERVOIR DRAIN AUDIBLE amp VISUAL ALARM 1571 REAR VIEW OPTIONAL CONTROLLER WITH 1963 GRAPHIC PANEL tank to from Toconvert to cm multiply by 2 54 Add to height dimension based on mounting options Weight is for standard chiller Some optional features will increase weight Multiply Ibs by 0 454 to calculate Kg Operating weight is with a full 20 gallon 76 reservoir tank of water 2 40 HP Port
53. e line sizing is based on the velocity required for sufficient oil return back to the compressor See Figure 4 on page 22 for discharge line sizing 2 40 HP Portable Chillers Chapter 3 Installation 21 of 78 Figure 2 Equivalent Length Feet for Valves Fittings Line Size Globe Valve Angle Valve Short Radius Elbow Long Radius Elbow Inches OD Equivalent Ft Equivalent Ft Equivalent Ft Equivalent Ft 1 2 43 15 1 4 0 9 5 8 55 18 1 6 1 0 7 8 69 24 2 0 14 11 8 87 29 2 7 1 9 13 8 102 33 3 2 2 2 1 5 8 115 34 3 8 2 6 2 1 8 141 39 5 2 3 4 2 5 8 159 44 6 5 42 Figure 3 Liquid Line Sizing 30 65 F Leaving Water Temperature Liquid Line Size O D Eqiv FT 5 hp 7 5 hp 10 hp 15 hp 20 hp 25 hp 30 hp 35 hp 40 hp 25 5 8 5 8 5 8 7 8 7 8 7 8 7 8 118 8 50 5 8 5 8 5 8 7 8 7 8 7 8 7 8 118 8 75 5 8 5 8 5 8 7 8 7 8 7 8 7 8 118 8 100 5 8 5 8 5 8 7 8 7 8 7 8 7 8 118 8 125 5 8 5 8 7 8 7 8 7 8 7 8 118 118 8 150 5 8 5 8 7 8 7 8 7 8 11 8 118 118 8 175 5 8 5 8 7 8 7 8 7 8 11 8 11 8 118 8 200 5 8 5 8 7 8 7 8 7 8 11 8 118 118 8 225 5 8 5 8 7 8 7 8 118 11 8 1 1 8 118 3 8 250 5 8 5 8 7 8 7 8 11 8 11 8 11 8 11 8 3 8 275 5 8 5 8 7 8 7 8 11 8 11 8 11 8 11 8 3 8 300 5 8 5 8 7 8 7 8 11 8 11 8 11 8 13 8 3 8 Figure 4 Discharge Line Sizing 30 65 F
54. ecific to your machine is provided with your shipping paperwork package Refer to this section for a listing of spare parts for purchase Have your serial number and model number ready when ordering Safety Symbols Used in this Manual The following safety alert symbols are used to alert you to potential personal injury hazards Obey all safety messages that follow these symbols to avoid possible injury or death Danger DANGER indicates an imminently hazardous situation which if not avoided will result in death or serious injury Warning WARNING indicates a potentially hazardous situation or practice which if not avoided could result in death or serious injury Caution CAUTION indicates a potentially hazardous situation or practice which if not avoided may result in minor or moderate injury or in property damage 2 40 HP Portable Chillers Chapter 1 Safety 6 of 78 1 2 Warnings Precautions equipment 15 designed to provide safe reliable operation when installed and operated within design specifications following national and local safety codes To avoid possible personal injury or equipment damage when installing operating or maintaining this equipment use good judgment and follow these safe practices Follow all SAFETY CODES Wear SAFETY GLASSES and WORK GLOVES Disconnect and or lock out power before servicing or maintaining the equipment Use care when LOADING UNLOADING RIGGING MOV
55. ene lycol Propylene Glycol 0 0 10 0 Temperature F 20 0 30 0 40 0 50 0 60 0 0 0 2 40 HP Portable Chillers 10 0 20 0 30 0 40 Glycol by Volume Example 45 F set point minus 20 F 25 F 0 50 0 From Figure 28 25 F equates to 10 by volume of glycol required Chapter 3 Installation 60 0 26 of 78 3 10 Automatic Water Make Up Option The chiller may be connected to an automatic make up system if the optional package float switch pressure regulating pipe fittings solenoid valve and 1 2 NPT city water make up connection is factory installed Refer to the typical piping schematics on pages 64 69 in the Appendix for additional components necessary for this installation 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 If the automatic make up system is connected to a city water system make provisions to prevent backflow contamination Install an approved backflow preventer in accordance with local codes Caution Adding straight city water into a glycol water mixture dilutes the solution and eventually leads to system freeze up Damage from freeze up is not covered by the warranty To prevent system freeze up in automatic make up applications we recommend using either a che
56. ents below 95 F 35 Crankcase Pressure Regulating CPR Valve Required on chillers operating at leaving water temperatures from 66 F to 75 F 10 C to 24 C This valve prevents compressor motor overloading 2 40 HP Portable Chillers Chapter 2 Functional Description 14 of 78 Stainless Steel Reservoir 5 hp to 30 hp models only Standard 35 hp and 40 hp models Manufactured from 304 stainless steel Mounting Features Locking 5 swivel casters with brake optional on air and water cooled 5 hp to 15 hp models e Mounting rails standard on remote air cooled models optional on other models Mounting rails with feet Optional Operating Voltages 380 3 50 volt available on 5 hp to 40 hp models only Consult factory for other voltages UL Labeled Electrical Subpanel Provides for the subpanel to be listed with Underwriters Laboratory with UL related benefits and features Optional Pumps Pump options are available for greater pressure and flow rates A recirculation pump is required whenever process water flow is less than 2 2 gpm per ton or greater than 4 8 gpm per tone See Figure 1 on page 16 for optional pump amperages NEMA 12 Electrical Enclosure 5 hp to 40 hp models only Provides for NEMA 12 level electrical enclosure protection Includes an accessible protective window kit over the graphic control panel NEMA 12 Control Access Door Includes an accessible protective window kit over the graphic control
57. er this warranty is the responsibility of the purchaser The manufacturer neither assumes nor authorizes any other persons to assume for it any liability in connection with the sale of its equipment not expressed in this warranty Many types of the manufacturer s equipment carry an additional one year service policy Consult your sales representative for specific details 2 40 HP Portable Chillers Chapter 7 Appendix 43 of 78 7 2 Technical Assistance Parts Department Call toll free 5 CST 800 423 3183 or call 414 354 0970 Fax 414 354 6421 The ACS Customer Service Group will provide your company with genuine OEM quality parts manufactured to engineering design specifications which will maximize your equipment s performance and efficiency To assist in expediting your phone or fax order please have the model and serial number of your unit when you contact us A customer replacement parts list is included in this manual for your convenience ACS welcomes inquiries on all your parts needs and is dedicated to providing excellent customer service Service Department Call toll free 8am 5pm CST 800 657 4679 or call 414 354 0970 Emergencies after 5pm CST call 847 439 5655 We have a qualified service department ready to help Service contracts are available for most of our products Sales Department Call 414 354 0970 Monday Friday 8am 5pm CST Our products are sold by a world wide network of independent s
58. ers Caution Do not connect make up water directly to the chilled water reservoir unless you have an approved automatic water make up system installed The reservoir is not designed to withstand water pressure The fill opening and vent line must be vented to the atmosphere for proper operation The optional automatic make up system is described in section 3 10 on page 27 Caution Do not pressurize tank Fill and vent lines must be open to atmosphere Supply and return connections must be trapped and vented to allow vertical risers to drain into tank Do not overfill system Allow enough free space in tank for vertical piping to drain If your application has chilled water or process piping above the reservoir fill and vent level trap and vent the supply and return lines to allow vertical piping to drain into tank See page 64 Note In applications where the process or process piping is above the reservoir 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 a vacuum breaker should be installed at the high point of the To Process and From Process lines See page 64 2 40 HP Portable Chillers Chapter 3 Installation 25 of 78 Figure 6 Ethylene Glycol and Propylene Glycol Curves 40 0 Percent Glyc ol Curves for Free ze Protec tion 30 0 20 0 10 0 Eth yl
59. escription section outlines models covered standard features and optional features Additional sections within the manual provide instructions for installation pre operational procedures operation preventive maintenance and corrective maintenance The Installation chapter includes required data for receiving unpacking inspecting and setup of the equipment We can also provide the assistance of a factory trained technician to help train your operator s for a nominal charge This section includes instructions checks and adjustments that should be followed before commencing with operation of the equipment These instructions are intended to supplement standard shop procedures performed at shift daily and weekly intervals The Operation chapter includes a description of electrical and mechanical controls in addition to information for operating the equipment safely and efficiently The Maintenance chapter is intended to serve as a source of detailed assembly and disassembly instructions for those areas of the equipment requiring service Preventive maintenance sections are included to ensure that your equipment provides excellent long service The Troubleshooting chapter serves as a guide for identification of most common problems Potential problems are listed along with possible causes and related solutions The Appendix contains technical specifications drawings schematics and parts lists A spare parts list with part numbers sp
60. g from the pump curve you selected then subtract the one pump pressure drop listed in the above table using the appropriate chiller hp and flow rate e For two pump Process Recirc chillers do not subtract pressure drop from table above for process pump 2 40 HP Portable Chillers Chapter 7 Appendix 60 of 78 Flow Pressure Considerations Model Design flow Design A P Standard pump power To Process pressure ipm psig Lkw psi kPa 30 4 AJ 2 hp 3 5 hp A R 5 hp R 7 5 hp R 10 hp R 15 hp A R 20 hp Modelo A 2hp 35hp A R 5hp A R 7 5 hp A R 10 hp A R 15 hp A R 20 hp A 25 hp A R 30hp 702 R35hp R40hp W2hp W35hp W5hp W7 5hp W10hp W W20hp 1 492 299 0 4 1321 1 492 262 1 5 175 9 372 3 TAJN NIDA 25 hp 2 2164 R 30 hp 35 hp 2782 5 59 4413 4 N 559 R 40 hp 88 0 3354 82 W2hp W 3 5 hp W5hp W 7 5 hp W 10 hp 15 hp 2 20 50 20 621 5 3 3 W 35 hp 820 310 4 5 4 37 2 7 5 5 59 64 0 441 3 44 A Air cooled W Water cooled R Remote Air cooled N o EN 2 2 2 2 3 2 3 3 3 3 2 2 2 2 2 4 3 4 3 0 6 7 6 3 4 8 3 2 4 2 9 4 oo
61. g normal operation the green SV LED on controller displays the process set point you P g want the chiller to maintain It also displays parameter and pre set function values during set up Out 1 LED The orange LED lights when the control OUT1 output energizes the hot gas bypass solenoid valve _ Out 2 LED The orange OUT2 LED lights whenever the OUT2 process temperature 15 two degrees or more above the To Process setpoint The compressor then comes on and runs until the temperature at the Process thermocouple is two degrees below the setpoint MANU LED The orange MANU LED is not used and does not MANU light Stop LED The orange STOP LED 15 not used and does not STOP light RMT LED The orange RMT LED is lit during remote RMT operation AT LED The orange AT LED flashes during auto tuning AT 2 40 HP Portable Chillers Chapter 4 Operation 29 of 78 Indicator Name Description SUB1 SUB 1 LED The orange SUB1 LED lights when the process temperature is two degrees or more below the To Process setpoint The compressor then shuts down by means of a latching circuit and it does not run again until the temperature at the To Process thermocouple is two degrees above the setpoint AT AutoTune Key Press and hold the AT key for two seconds to initiate or stop the auto tune function functions of t
62. he Display key change based how long you press it Press the Display key for less than one 1 second to scroll through parameters within the mode Down Arrow Key Each press of the Down Arrow key decrements or reduces values or settings on the SV display Up Arrow Key Each press of the Up Arrow key increments or advances the values or settings on the SV display Sterlco 2000 Controller Indicator Name Description e en Process Value LED During normal operation the large red T LED on the controller displays the actual process temperature at the Process thermocouple It also lists parameter symbols during setup and error messages if an error occurs y 55 Set Value LED During normal operation the green SP LED on the controller displays the process set point you want the chiller to maintain It also displays parameter and pre set function values during set up Index Key Press the Index key for less than 1 second to scroll through parameters within the mode Up Arrow Key Each press of the Up Arrow key increments or advances the values or settings on the SP display Down Arrow Key Each press of the Down Arrow key decrements or reduces the values or settings on the SP display Enter Key Press the Enter key to verify or confirm an entry 2 40 HP Portable
63. he maintenance and operation of the machine All personnel engaged in the use of the machine should become familiar with its operation as described in this manual Proper operation of the machine promotes safety for the operator and all workers in its vicinity Each individual must take responsibility for observing the prescribed safety rules as outlined All warning and danger signs must be observed and obeyed All actual or potential danger areas must be reported to your immediate supervisor 2 40 HP Portable Chillers Chapter 1 Safety 7 of 78 Chapter 2 Functional Description 2 1 Models Covered in This Manual This manual provides operation installation and maintenance instructions for air and water cooled portable chillers Model numbers are listed on the serial tag Make sure you know the model and serial number of your equipment before contacting the manufacturer for parts or service Our portable chiller models are designated by approximate compressor horsepower 2 3 1 2 5 7 1 2 10 etc and the cooling method used A for air cooled W for water cooled and R for remote air cooled 2 40 HP Portable Chillers Chapter 2 Functional Description 8 of 78 2 2 General Description Our portable chillers are reliable accurate and easy to use process cooling units They are available in air water and remote air cooled designs in a range of sizes from 2 to 40 tons All are self contained fully portable and shipped ready
64. hillers Nominal operating parameters for remote air cooled models are 50 F 10 C leaving water temperature at 2 4 gpm per ton 9 1 Ipm per 3 517 kW with 95 F 35 C ambient air For 50 Hz applications multiply capacity by 0 83 Nominal 60 Hz capacity flow rate must be maintained Nominal cooling Nom Com Refrigeration Power in amps capacity tons water pres Nom connections 460 3 60 in dia ODS 1 2pumps Discharge Liquid rated running rated Based 50 F 10 C chilled water supply temperature and 95 F 35 C ambient air Optional additional process pump hp reduces chiller capacity by 0 2 tons per hp 0 703 kW ref cap per 0 746 kW pump power Based 2 4 gpm per ton 9 1 per 3 517 kW nominal 1 pump An optional oversized process pump adds to the total rated or running chiller amperage To find the new total chiller amperage subtract the standard process pump amperage from the optional pump amperage see Figure 1 on page 16 and add it to the chiller rated or running amperage Multiply 460 3 60 amperage by 2 0 for 208 230 3 60 amperages multiply by 0 8 for 575 3 60 amperages e x s 5 46 49 28 11 e 47 eoo x N 7 n RAILS FEET MOUNTING DETAILS 34 00 OPTICS PROCESS SUPPLY OPTIONAL RESERVOIR VENT amp OPTICS PROCESS RETURN AUTO WATER m OPTIONAL MAKE UP SUPPLY OP
65. hrough 40 hp No Pump Models 68 Typical Piping Schematic 5 hp through 40 hp One Pump Models 69 7 8 Electrical Schematics 70 Typical Electrical a Een Dae Aae A AEAEE 70 Typical Electrical Schematic 2 hp 3 1 2 hp 5 71 Typical Power Wiring Schematic 5 hp through 40 hp Models 72 Typical Wiring Schematic 5 hp through 15 hp Models with Pump 73 Typical Wiring Schematic 5 hp through 15 hp Models without Pump 74 Typical Wiring Schematic 20 hp through 30 hp Models with Pump 75 Typical Wiring Schematic 20 hp through 30 hp Models without 76 Typical Wiring Schematic 35 hp and 40 hp Models with 77 Typical Wiring Schematic 35 hp and 40 hp Models without Pump 78 2 40 HP Portable Chillers Chapter 1 Safety 1 1 How to Use This Manual Use this manual as a guide and reference for installing operating and maintaining your equipment The purpose is to assist you in applying efficient proven techniques that enhance equipment productivity This manual covers only light corrective maintenance No other maintenance should be undertaken without first contacting a service engineer The Functional D
66. in an RMA return material authorization number If the Shipment is Not Complete Check the packing list as back ordered items are noted on the packing list In addition to the equipment itself you should have Bill of lading Packing list Operating and Installation packet Electrical schematic and panel layout drawings Component instruction manuals if applicable Re inspect the container and packing material to see if you missed any smaller items during unpacking If the Shipment is Not Correct If the shipment is not what you ordered contact the shipping department immediately For shipments in the United States and Canada call 1 800 783 7835 for all other countries call our international desk at 414 354 0970 Have the order number and item number available Hold the items until you receive shipping instructions Returns Do not return any damaged or incorrect items until you receive shipping instructions from the shipping department 2 40 HP Portable Chillers ii Table of Contents CHAPTER 1 SAFETY 6 1 1 How to Use This Manual a a 6 Safety Symbols Used in this 6 1 2 Warnings and Precautions ERR SQ fe 7 152 p mH IM 7 CHAPTER 2 FUNCTIONAL DESCRIPTION 8
67. iping Y strainer requires periodic cleaning of its screen to insure the proper flow through the evaporator To clean the strainer screen remove the access plug and retaining cap and pull out the screen Wipe brush or vacuum out any dirt left in the strainer body Clean the screen and replace it in the strainer taking care to fit it squarely into the machined seat provided Caution Do not forget to re install the screen after cleaning it Operating the chiller with no strainer screen can potentially plug the evaporator with dirt The warranty does not cover chiller failures from a dirty evaporator 2 40 HP Portable Chillers Chapter 5 Maintenance 39 of 78 5 6 Preventative Maintenance Service Follow a systematic preventive maintenance program to help avoid costly down time Call the Service Department to arrange a schedule of inspections This service be tailored to fit your maintenance requirements These inspections include but are not limited to Checking refrigerant suction and discharge pressures Checking safety and operating conditions Checking voltage and amperage of all motors Checking all electrical connections Checking quantity of refrigerant Checking compressor oil level Checking lubrication of motor and pump bearings Checking circulating pump operation Checking flow through heat exchangers Checking compressor efficiency Checking noise levels 2 40 HP Portable Chillers Chapter 5 Maintenance 40 of 78 Chapter
68. ith a full 80 gallon 303 liter reservoir tank of water 2 40 HP Portable Chillers Chapter 7 Appendix 48 of 78 2 3 5 Water Cooled Portable Chillers Nominal operating parameters for water cooled models 50 F 10 C leaving water temperature at 2 4 per ton 9 1 Ipm per 3 517 kW with 85 F 29 C tower water For 50 Hz applications multiply capacity by 0 83 Nominal 60 Hz capacity flow rate must be maintained Nominal N water Com Amp draws pressor pump pump gom O hp hp T water water rated running 2 0 1 0 6 2 4 2 ominal cooling pacity in tons 1 pump 2 2 1 1 9 1 0 12 2 8 3 5 1 35 36 34 86 35 to 10 105 72 164 118 Based 50 10 chilled water supply temperature 85 29 tower water Optional additional process pump hp kW reduces chiller capacity by 0 2 tons per hp 0 703 kW ref cap per 0 746 kW pump power Based on 2 4 gpm per ton 9 1 Ipm per 3 517 kW nominal 1 pump Based on availability of 85 F 29 C tower water at 25 psi 172 4 kPa 1 7 bars minimum Based on availability of 70 F 21 C city water at 25 psi 172 4 kPa 1 7 bars minimum optional oversized process pump adds to the total rated or running chiller amperage To find the new total chiller amperage subtract the standard
69. lar metals PVC or non ferrous piping is recommended to reduce galvanic action If iron piping must be used use dielectric unions at the chiller 3 6 Water Treatment Considerations Water treatment is an integral part of the system In some locations water may cause large deposits of scale erosion algae and or corrosion The use of poor quality water may result in inefficient operation heat exchanger damage and pump seal damage Consult a qualified water treatment specialist to determine whether treatment is needed We offer a complete line of water treatment equipment Contact your sales representative for water testing and treatment options 2 40 HP Portable Chillers Chapter 3 Installation 18 of 78 3 7 Considerations Water Cooled Chiller Condensers Water cooled portable chillers can use city water or tower water as a cooling medium Make sure that all external piping and connections supplying and discharging water to and from the condenser are full size You ll make two connections to the water cooled condenser Condenser Water In The condenser water supply labeled Condenser Water is located at the rear of the chiller It is the inlet for city or tower water Make sure that water is supplied at a maximum temperature of 85 F 29 C and a minimum pressure of 25 psi Caution The water regulating valve is set at the factory Only a qualified refrigeration technician should adjust it
70. le Chillers Chapter 7 Appendix 51 of 78 20 hp 25 30 Water Cooled Portable Chillers Nominal operating parameters for water cooled models 50 F 10 C leaving water temperature at 2 4 per ton 9 1 Ipm per 3 517 kW with 85 F 29 C tower water For 50 Hz applications multiply capacity by 0 83 Nominal 60 Hz capacity flow rate must be maintained Nominal cooling Power in amps capacity tons water flowin gpm 460 3 60 Tower City 1 2pumps in NPT water Wwater frated running rated running 0 Based on 50 F 10 C chilled water supply temperature and 85 F 29 C tower water Optional additional process pump hp reduces chiller capacity by 0 2 tons per hp 0 703 kW ref cap per 0 746 kW pump power Based 2 4 gpm per ton 9 1 Ipm per 3 517 kW nominal 1 pump Based on availability of 85 F 29 C tower water at 25 psi 172 4 kPa 1 7 bars minimum Based on availability of 70 F 21 C city water at 25 psi 172 4 kPa 1 7 bars minimum An optional oversized process pump adds to the total rated or running chiller amperage To find the new total chiller amperage subtract the standard process pump amperage from the optional pump amperage see Figure 1 on page 16 and add it to the chiller rated or running amperage Multiply 460 3 60 amperage by 2 0 for 208 230 3 60 amperages Err RESERVOIR VENT 5 46 95 28
71. le visual alarm option ALARM This switch is always provided and requires no additional wiring if either alarm option is installed at a later time 2 40 HP Portable Chillers Chapter 4 Operation 33 of 78 Figure 8 Typical Graphic Panels With E5CK Controller COMPRESSOR ON HOT GAS BY PASS PUMP ON PUMP OVERLOAD O LOW WATER FLOWIPRESSURE CONTROL POWER A0554705 With Sterlco 2000 Controller COMPRESSOR ON HOT GAS BY PASS PUMP ON PUMP OVERLOAD LOW WATER FLOW PRESSURE IN U S A CONTROL POWER A0554705 2 40 HP Portable Chillers Chapter 4 Operation O LOW TEMPERATURE HIGH TEMPERATURE HIGH DISCHARGE TEMPERATURE HIGH REFRIGERANT PRESSURE LOW REFRIGERANT PRESSURE LOW OIL PRESSURE ALARM SILENCE O O LOW TEMPERATURE HIGH TEMPERATURE HIGH DISCHARGE TEMPERATURE HIGH REFRIGERANT PRESSURE LOW REFRIGERANT PRESSURE LOW OIL PRESSURE ALARM SILENCE O 34 of 78 4 2 Start up 1 Turn on the chiller and put it under process load 2 Setthe controller for the To Process temperature you want using the Up Arrow button or the Down Arrow button located on the face of the controller 3 Adjust the High Low thermostat located in the electrical en
72. led Chillers Proper water treatment will greatly reduce cleaning intervals Coaxial Condensers 2 to 7 5 hp chillers Remove dirt and slime in the condenser tube water side by reverse circulating with a mild detergent and water solution Remove mineral deposits by reverse circulating Liquid Inhibited Acid De Scaling Solution Part No A0502600 through the water side of the condenser Follow the directions on the container Shell amp Tube Condensers 10 to 40 hp chillers Remove dirt and slime in the condenser tube water side by cleaning with a nylon tube brush Remove mineral deposits by reverse circulating Liquid Inhibited Acid De Scaling Solution Part No A0502600 through the tube water side of the condenser Follow the directions on the container The refrigerant side is sealed and requires no routine maintenance Caution Do not use steam or water over 140 F 60 C to clean a condenser unless you are monitoring the refrigeration circuit for excessive pressure with gauges Only a trained technician should use this method 5 4 Maintaining the Evaporator Dirty evaporator heat exchange surfaces reduce system capacity and efficiency Remove dirt and slime in the evaporator by reverse circulating with a mild detergent and water solution Remove mineral deposits by reverse circulating Liquid Citric Acid De Scaling Solution Part No A0536607 Follow the directions on the container 5 5 Evaporator Process Piping Y Strainer The process p
73. many as three times before leveling off and controlling the process set point Auto Tuning can take up to 45 minutes and is best done before any product is being run 1 Press and hold down the AT key for several seconds until the AT indicator flashes 2 When the AT LED light stops flashing the controller is tuned and ready for operation 4 5 Optional Communications The communications function allows you to monitor and set controller parameters by a program prepared and running on a host computer connected to the controller When using the communications function you must add on the unit for RS 232C or RS 485 communications The controller communications function allows you to read write parameters do operating instructions and select the setting level 2 40 HP Portable Chillers Chapter 4 Operation 35 of 78 4 6 Programming the Electronic High Low Thermostat The thermostat control is located in the chiller enclosure The control has three control keys and a one line four character LCD display The thermostat control has a lockout slide switch to prevent tampering by unauthorized personnel The switch is located on the inside cover of the thermostat The keypad is disabled when the switch is moved to the left in the Lock position The keypad functions normally when the switch is moved to the right in the Unlock position All chillers are shipped with the switch in the Lock position Thermostat Buttons Indicat
74. mical feeder or make up reservoir to replenish glycol Contact the sales department for more information about these configurations 2 40 HP Portable Chillers Chapter 3 Installation 27 of 78 3 11 Initial Start Up e 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 Portable chillers are built with a voltage specific compressor and cannot be re wired for an alternate voltage e 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 plus or minus ten percent 10 of the voltage listed on the serial tag Electrical connections must conform to all applicable codes Complete chilled water To Process and From Process connections e Make sure the chilled water To and From process valves on the chiller are 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 11 C below the leaving water temperature you want The air cooled condenser should have an adequate supply of 60 to 95 F 16 to 35 air for proper operation The tower or city water condenser cooling in and out connections should be completed and an adequate supply of 85 F 30 C tower or 70 F 21 C city water at
75. n reverse 2 40 HP Portable Chillers Chapter 6 Troubleshooting 42 of 78 Chapter 7 Appendix 7 1 Warranty We warrant all of our equipment to be free from defects in workmanship and material when used under recommended conditions The manufacturer s obligation is limited to repair or replace FOB the factory any parts that are returned prepaid within one year of equipment shipment to the original purchaser and which the manufacturer s opinion are defective Any replacement part assumes the unused portion of this warranty This parts warranty does not cover any labor charges for replacement of parts adjustment repairs or any other work This warranty does not apply to any equipment which in the manufacturer s opinion has been subjected to misuse negligence or operation in excess of recommended limits including freezing or which has been repaired or altered without the manufacturer s express authorization If the serial number has been defaced or removed from the component the warranty on that component is void Defective parts become the property of the warrantor and are to be returned The manufacturer is not liable for any incidental consequential or special damages or expenses The manufacturer s obligation for parts not furnished as components of its manufactured equipment is limited to the warranty of the manufacturers of said parts Any sales use excise or other tax incident to the replacement of parts und
76. nd 7 5 hp Remote Air Cooled Portable 54 10 hp and 15 hp Remote Air Cooled Portable 55 20 hp through 40 hp Remote Air Cooled Portable Chillers 56 Remote Condenser Assembly 57 7 4 Pump Curves Flow and Pressure Considerations 58 60 Hertz PUMP BAR A aede ass ee TN Eee dens 58 50 Hertz Pump CUIVES x o eeu dete ever Evo tie dea Pd dete ev 59 Water Pressure Drop Tables sessi nnn 60 2 40 HP Portable Chillers iv Flow Pressure Considerations 61 Recirculation Pump 5 61 7 5 Remote Air Cooled Chiller Configurations 62 7 6 Typical Ductwork for Air Cooled 63 7 7 Piping Diagrams 64 Central and Gravity Return Piping with Standpipe Diagram 64 Typical Piping Schematic 2 and 3 1 2 hp 65 Typical Piping Schematic 5 hp through 40 hp One Pump Models 66 Typical Piping Schematic 5 hp through 40 hp Two Pump Models 67 Typical Piping Schematic 5 hp t
77. ndard chiller Some optional features will increase weight Operating weight is with a full 80 gallon 303 liter reservoir tank of water 2 40 HP Portable Chillers Chapter 7 Appendix 56 of 78 Remote Condenser Assembly Models Remote Condenser Refrigeration represents electrical phase all motors are 1 140 rpm Multiply hp by 0 746 to convert to kW All first fan motors Header Side are hp 0 56 kW single phase variable speed Multiply 460V amperages by 2 0 for 208 230V amperages Multiply 460 V amperages by 0 8 for 575 V amperages Refrigeration charge is for remote condenser only To convert cfm to cmh multiply by 1 699 To convert Ibs to Kg multiply by 0 454 See drawing above 2 40 Portable Chillers Chapter 7 Appendix 57 of 78 8L JO 8 xipu ddv soydey dH Ot c 0 ON s mn 09 SUOI JEJOPISUOD pue s nin 8L JO 6 xipu ddv 4 dH Ot c 60874506 ON TOO LI EID Ti Mell PR 3122227 ETIN S gd gg gp HE pnr TE TEL IH j Ir il i TOT LLL ji il S i H HEDI s L
78. ng or for Heating Use the Up Arrow and Down Arrow keys to toggle between 1 or H1 The setting should be Stage 2 High Temperature Protection 5 Press the Set key again to access the high temperature set point The screen displays the current set point and the S2 indicator blinks on and off to indicate that the control Is In set point mode Use the Up Arrow and Down Arrow keys to adjust the set point The setting should be 100 38 6 Press Set key to access Stage 2 differential screen displays the current differential and the DIF2 indicator blinks on and off to indicate that the control is in differential mode Use the Up Arrow and Down Arrow keys to adjust the differential The setting should be 2 F 7 Press the Set key again to access Stage 2 cooling or heating mode The screen displays the current mode for cooling for Heating Use the Up Arrow and Down Arrow keys to toggle between C1 and H1 The setting should 2 40 HP Portable Chillers Chapter 4 Operation 37 of 78 Chapter 5 Maintenance 5 1 Lubrication Grease all blower bearings fan and blower motors and pump motors that do not have permanently sealed bearings Remove the grease relief plug motors only before adding grease add grease until a small amount pours out and replace the plug when finished Caution Failure to remove the grease relief plug will result in dislodging the bearing grease se
79. or Name Description Set Button The Set button is used to enter the programming mode for the thermostat Up Arrow button Each press of the Down Arrow key decrements or reduces values or settings on the display Down Arrow Each press of the Up Arrow key increments or button advances the values or settings on the display 2 40 HP Portable Chillers Chapter 4 Operation 36 of 78 Perform following procedures to program the electronic High Low Thermostat control Select Fahrenheit or Celsius 1 Press the Set key once to access Fahrenheit Celsius mode Use the Up Arrow and Down Arrow keys to toggle between Fahrenheit and Celsius Stage 1 Freeze Protection 2 Press the Set key again to access the low temperature set point The screen displays the current set point and the S1 indicator blinks on and off to indicate that the control Is In set point mode Use the Up Arrow and Down Arrow keys to adjust the set point At 50 F 10 C leaving water temperature the setting should be 42 F 6 C 3 Press the Set key again to access the Stage 1 differential The screen displays the current differential and the DIF1 indicator blinks on and off to indicate that the control is in differential mode Use the Up Arrow and Down Arrow keys to adjust the differential The setting should be 12 F 4 Press the Set key again to access Stage 1 cooling or heating mode The screen displays the current mode for cooli
80. or running chiller amperage To find the new total chiller amperage subtract the standard process pump amperage from the optional pump amperage see Figure 1 on page 16 and add it to the chiller rated or running amperage Multiply 460 3 60 amperage by 2 0 for 208 230 3 60 amperages G To convert cfm to cmh multiply by 1 699 1 22 00 a E 55 9 LA e AS Top view out lt bi Air in gt lt Air in Process Bypass filter flow 3 5 hp pressure gauge meter optional 2 6 kW To Process 1 only Bypass filter 200 7514 4 m Auto water makeup supply optional 49 66 A Controller with i E optional graphic panel he Disconnect 12810m o 1 Reservoir vent Hour meter k amp fill 3 4 inside B optional i m Reservoir ET 18 44 sight glass 20 Audible amp visual 50 8 alarm optional gt From Process kaz s s Electrical enclosure Reservoir drain i y Right side view A0562439 Front view Electrical power supply access 2 and 3 1 2 hp portable chillers come standard with 2 1 2 63 mm swivel casters Process Dimensions Compressor connections inches DryO Ship inNPT height i
81. ovide protection down to 20 F 11 C below the operating To Process temperature you want You can then reset the high low thermostat cutout temperature to a temperature 8 F 4 4 C below the operating temperature you want Stage two of the high low thermostat shuts down the pumps therefore shutting off the chiller if the chilled process water glycol temperature rises above the selected cutout point This prevents possible damage to the complete process piping system due to overheating of the components by the process water glycol The thermostat stage two cutout temperature is factory set at 100 F 38 C See Section 4 6 on page 36 for information about changing the thermostat settings Caution Protect the system from freezing with glycol 20 F below the leaving water temperature set point Condensation may form inside the pump tank and dilute the mixture therefore the freezing point should be verified periodically See Figure 6 on page 26 for the correct mixture Caution Set high low thermostat cutout temperature 8 F below the set point leaving water temperature Crankcase Heater 5 hp through 40 hp portable chillers have a crankcase heater It is wired through the control transformer that operates continuously whenever power is applied to the chiller Caution Energize the crankcase heater for at least 24 hours before initial startup to drive dissolved refrigerant from the compressor oil Failure to do so will damage the comp
82. panel 2 40 HP Portable Chillers Chapter 2 Functional Description 15 of 78 Figure 1 Optional Pump Amperages 2 40 HP Portable Chillers Voltage Construction HP Full Load Amps 208 230 1 60 Bronze Turbine 75 5 4 55 1 6 4 1 5 7 5 2 9 6 3 12 7 460 3 60 Bronze Turbine 75 1 5 55 1 1 8 1 5 2 3 2 3 1 3 42 5 6 2 7 5 9 8 10 13 2 15 19 0 Dual SS 2 27 3 4 5 5 6 6 75 9 0 Chapter 2 Functional Description 16 of 78 Chapter 3 Installation 3 1 Uncrating 2 hp to 5 hp models are shipped mounted on a skid enclosed in a plastic wrapper and contained in a cardboard box 7 5 to 40 hp models are shipped mounted on a skid enclosed in a plastic wrapper and open crated on all four sides and top 1 Pry the crating away from the skid Note 2 to 5 hp models remove the nails holding the box to the skid and lift the box off carefully avoiding staples in the I x 4 wood supports Cut the steel banding 2 Use a pry bar to remove the blocks securing the unit to the skid 3 Lift unit from sides inserting forklift under the base The forks must be equidistant from the centerline of the unit and the unit must be balanced on the forks 20 hp to 40 hp units feature special lifting openings Lift slowly and only high enough to clear the skid Use a pry bar if necessary to carefully remove the skid from the unit 4 Lower slowly The unit should land on its
83. pe O D Discharge Line Liquid Line R 22 Inches R 22 Lbs R 22 Lbs 72 p ew ss Based 100 feet of pipe 100 F Liquid 100 F Discharge Oil Charge Determination The remote air cooled portable chillers are factory charged with the amount of oil required without field installed piping Additional oil required is dependent on the amount of additional refrigerant added Calculate the amount of additional oil required by using the following formula Pints of oil Sunisco 3GS lbs of R 22 added for field installed piping 100 2 40 HP Portable Chillers Chapter 3 Installation 23 of 78 3 8 Checking Motor Direction All of our portable chillers have their motor rotations properly phased at the factory If compressors pumps or fans are running in reverse rotation disconnect and lock out the power source and reverse any two power leads into the chiller disconnect switch Caution Do not switch leads at the motors motor starters or contactors Three Phase Compressors Scroll compressors are directionally dependent and compress in one rotational direction Reversing rotation direction results in an elevated sound level and a substantially reduced current draw Water Pumps Correct pump rotation is indicated by a positive pressure of 20 to 40 psi on the pump pressure gauge Pump rotation should be clockwise when viewed from the motor end For chillers with optional pumps check the appropriate pump c
84. pip ep oes Je os soAn2 06 Water Pressure Drop Tables Note A recirculation pump is required for flows greater than the maximum or less than the minimum indicated Note Process flow less than or greater than the flow rates shown below requires a recirculation pump Pressure drops in AP psig and kPa E 7 5 Fow Fo Fo Fo apm psig kPa ipm psig kPa gpm ipm psig kha gpm psig kPa 201 6 530 130 896 24 0 908 73 502 474 tear 9 6 659 25 AP Fo Fiw Fo gem ipm psig kPa apm fom psig kea fem psig kPa pm kPa 1136 45 37 3 40 0 1514 4 0 0 113 6 1514 3 4 4 74 56 60 0 227 1 17 0 1968 60 414 pm psig kPa pm psig kPa psig kPa psig kPa 272 5 60 41 1 387 146 5 169 2 75 0 283 9 65 448 512 1938 107 1 02 5 2 5 8 2 70 6 4 3 8 9 8 81 0 6 3 5 313 7 105 7 400 0 Note These pressure drop values are valid for single and no pump portable chillers Calculating Chiller Nominal Flow and Pressure to Process Flow rate Obtain the flow reading from the appropriate pump curve e Pressure Obtain a corresponding pressure readin
85. process pump amperage from the optional pump amperage see Figure 1 on page 16 and add it to the chiller rated or running amperage Multiply 460 3 60 amperage by 2 0 for 208 230 3 60 amperages 2 41 68 S 105 9 stem G 55 9 cm 1 s Bypass filter flow Condenser Y meter optional view erase Process N Y Auto water eak vb da e ass filter X CN supply optional Controller with 3 Disconnect L3 pos NE u x graphic panel ZH Switch UJ n Hour meter n E Reservoir vent V o 2831 Gib on 2131 optional h 8 j m Reservoir 20 00 4 es Ee sen ws era ui Reservoir 1 _ 200154 4 LEM zt iic Front view U Right side view Rear view 1 66 Electrical power 566 supply access 2 hp and 3 5 hp water cooled portable chillers come standard with 2 63 mm swivel casters in NPT height width depth Ibs 283 220 417 333 10 283 220 417 362 To convert to cm multiply by 2 54 Add to height dimension based on mounting options Weight is for standard chiller Some optional features will increase weight Multiply by 0 454 to calculate Kg Operating weight is with a full 6 gallon 22 7 liter reservoir tank of water 1 0 1 0 2 40 HP Portable Chillers Chapter 7 Appen
86. ressor High Pressure Cutout This electro mechanical cutout device opens the compressor control circuit if the refrigeration system compressor discharge pressure exceeds 375 psi for an air cooled chiller and 290 psi for a water cooled chiller Note The high pressure cutout is a manual reset device typically mounted on the compressor discharge line inside the mechanical cabinet Call a refrigeration service technician to analyze the problem and reset the control 2 40 HP Portable Chillers Chapter 2 Functional Description 12 of 78 Low Pressure Cutout This electro mechanical cutout device opens the compressor control circuit if refrigeration system compressor suction pressure drops below 15 psi It automatically resets when refrigerant suction pressure reaches 30 psi Note The low pressure cutout is an automatic reset device typically mounted on the compressor suction line inside the mechanical cabinet Call a refrigeration service technician to analyze the problem and reset the control Oil Pressure Safety Switch This mechanical cutout device is installed on chillers built with semi hermetic compressors that have oil pumps A differential pressure switch monitors the difference between crankcase pressure and oil pump pressure If the pressure drops to an unsafe level for more than two minutes the switch opens the control wiring circuit shutting off the compressor and turning the light on but the pumps will continue running Not
87. table Chillers i 2 17 a aer auaa S 28 CHAPTER 4 OPERATION 29 4 1 Panel Buttons Indicator Lights and Switches 29 Microprocessor Controllers 29 Graphic Panel i uu iade tiet COTE HAT f OC M 32 4 2 c 35 4 3 Setting the Process Water Temperatures 35 MEE GO ME UI 35 4 5 Optional Communications nennen enne 35 4 6 Programming the Electronic High Low 36 CHAPTER 5 2 38 7EUDEFICALIOD erede AAAS Ae ee edP 38 9 2 SIT Me RP asa 38 53 Maintaining the Condenser 39 Air Remote Air Cooled Chillers 39 Water Cooled Chillers 39 5 4 Maintaining the Evaporator rint e e caves i Er rp RE Rd 39 5 5 Evaporator Process Piping 000000000000 nnne 39 5 6 Preventative Maintenance 40 CHAPTER 6 TROUBLESHOO
88. urve in the Appendix Caution Do not run pump dry Doing so will result in seal damage Condenser Fan Air should be drawn through the condenser and discharged vertically from the chiller 2 40 HP Portable Chillers Chapter 3 Installation 24 of 78 3 9 Water Reservoir All portable chillers shipped during the fall winter or spring or those units that are shipped from stock are flushed at the factory with a water ethylene glycol solution to prevent piping components prone to retaining water from freezing During startup and when additional solution is required refer to the ethylene glycol and propylene glycol curves in Figure 6 on page 26 Add a pre mixed solution of industrial quality not automotive ethylene glycol or propylene glycol and water to provide freeze protection to a temperature 20 F 11 C below the normal chiller operating temperature set point Glycol and or water with an inhibitor should be used to protect the materials copper steel stainless steel and bronze in the system from corrosion If you intend to use straight water we strongly advise a minimum leaving water temperature of 50 F 10 C or contact the service department The following glycol products are available Part Number Description A0541358 Ethylene glycol 5 gallons 18 9 liters A0539637 Ethylene glycol 55 gallons 208 2 liters A0542990 Propylene glycol 5 gallons 18 9 liters A0542991 Propylene glycol 55 gallons 208 2 lit
89. vity Return Piping with Standpipe Diagram VACUUM BREAKER VACUUM BREAKER ASSEMBLY ASSEMBLY CHECK a 1 8 HOLE CHECK D 1 8 HOLE VALVE VALVE 1 4 e PROCESS FROM PROCESS THE FILL AND VENT LINES MUST REMAIN OPEN TO ATMOSPHERE 00 FT VENT 6 1 m tl MAXIMUM W CHECK VALVE 0554830 INDICATES END OF PIPING RIGHT SIDE VIEW 2 40 HP Portable Chillers Chapter 7 Appendix 64 of 78 Typical Piping Schematic 2 and 3 1 2 hp Models 2 40 HP Portable Chillers Chapter 7 Appendix 65 of 78 Typical Piping Schematic 5 hp through 40 hp Models A E Y Vn eg 5679 2 40 HP Portable Chillers Chapter 7 Appendix 66 of 78 Typical Piping Schematic 5 hp through 40 hp Two Pump Models 2 40 Portable Chillers Chapter 7 Appendix 67 of 78 Typical Piping Schematic 5 hp through 40 No Pump Models 2 40 HP Portable Chillers Chapter 7 Appendix 68 of 78 Typical Piping Schematic 5 hp through 40 hp Models eee ise E Se 2 40 HP Portable Chillers Chapter 7 Appendix 69 of 78 7 8 Electrical Schematics Typical Electrical Subpanel Disconnect Switch Optional Fan Motor Speed Control Control High Low Transformer T stat 2 40 HP Portable Chillers Chapter 7 Appendix 70 of 78 Typical Electrical Schematic 2 hp 3 1 2 hp Models
90. water and remote air cooled refrigerant condensing differs only in the way compressed gas is condensed to a liquid Liquid refrigerant from the condenser heat exchanger flowing in the liquid line passes through a shut off valve 5 hp to 40 hp chillers only into a filter dryer that removes moisture and other contaminants A refrigerant sight glass is provided The refrigerant then passes through the thermal expansion valve which allows the refrigerant to expand boil off and cool the fluid inside of the evaporator The refrigerant gas flows through the suction linen back into the compressor The refrigerant is compressed in the compressor and flows through the discharge line as a gas to the condenser There it gives up its heat as it condenses to a liquid in the condenser A hot gas bypass valve is used to control cooling capacity during intermittent or partial load conditions This feature contributes substantially to chiller longevity by eliminating excessive cycling of the compressor and providing close temperature control 2 40 HP Portable Chillers Chapter 2 Functional Description 9 of 78 2 3 Standard Features Mechanical Features Compressor Hermetic scroll compressors are used on 2 hp through 30 hp 1 49 through 23 37 kW models Semi hermetic discus compressors are used on the 35 hp and 40 hp 26 20 and 29 83 kW models Evaporator Stainless steel copper brazed plate evaporators are used on 2 hp through 30 hp models Shell

HP A0554832 User's Manual

Contents

Download Pdf Manuals

Related Search

Related Contents