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2–40 hp Portable Chillers
Part Number: A0554831
Bulletin Number: SC2-610C.10
Effective: 4/3/2008
Write Down Your Serial Numbers Here For Future Reference:
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We are committed to a continuing program of product improvement.
Specifications, appearance, and dimensions described in this manual
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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
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Table of Contents CHAPTER 1: SAFETY ................................................................. 6 1-1 How to Use This Manual .............................................................................................6 Safety Symbols Used in this Manual.....................................................................6 1-2 Warnings and Precautions ..........................................................................................7 1-3 Responsibility.........................
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3-11 Initial Start-Up............................................................................................................28 CHAPTER 4: OPERATION ........................................................ 29 4-1 Panel Buttons, Indicator Lights, and Switches ..........................................................29 Microprocessor Controllers..................................................................................29 Graphic Panel................................................
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Flow and Pressure Considerations......................................................................61 Recirculation Pump Specifications ......................................................................61 7-5 Remote Air-Cooled Chiller Configurations ................................................................62 7-6 Typical Ductwork for Air-Cooled Chillers...................................................................63 7-7 Piping Diagrams.......................................
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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 Description section outlines models covered, standard features, and optional featu
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1-2 Warnings and Precautions Our equipment is designed to provide safe and 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
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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:
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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 to use. (Remote air-cooled chillers require field installation by qualified technicians.) Standard range of operation is 30ºF to 65ºF (-1ºC to 18ºC) for applications using a water/glycol mix and 45ºF to 65ºF (7º to 18ºC) fo
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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 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.
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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 10 hp models • High and low refrigerant pressure cutout switc
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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 low thermostat stage one cutout temperature is factory-set at 42ºF (5.5ºC). This is correct for a supply water temperature o
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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. Fan Cycling Switch Air-c
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2-5 Optional Features Options marked with “*” indicate options that can be factory installed or retrofitted in the field. Automatic Water Make-Up*. Not available on chillers less reservoir tank. Includes a 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 prov
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Mounting Features. • Locking 5” swivel casters with brake, optional on air- and water- cooled 5 hp to 15 hp models • 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
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Figure 1: Optional Pump Amperages Voltage Construction HP Full Load Amps 208-230/1/60 Bronze Turbine .75 5.4 SS 1 6.4 1.5 7.5 2 9.6 3 12.7 460/3/60 Bronze Turbine .75 1.5 SS 1 1.8 1.5 2.3 2 3.1 3 4.2 5 6.2 7.5 9.8 10 13.2 15 19.0 Dual SS 2 2.7 3 4.5 5 6.6 7.5 9.0 2-40 HP Portable Chillers Chapter 2: Functional Description 16 of 70
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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 1’ x 4’ wood supports. Cut the steel banding. 2
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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 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 i
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3-7 Condenser 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 In”, is located at the rear of the chiller. It is the inlet for city or tower water. Make
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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 nitrogen 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
