Related Manuals for Sterling 30F to 65F
Summary of Contents for Sterling 30F to 65F
- Page 1 OPERATION AND INSTALLATION MANUAL SMC SERIES AIR COOLED PORTABLE WATER CHILLERS IMPORTANT: PLEASE READ CAREFULLY BEFORE ATTEMPTING TO INSTALL OR OPERATE EQUIPMENT...
- Page 2 Sterling, Inc. is committed to a continuous program of product improvement. Specifications are subject to change without notice. © Sterling, Inc. 2003 All Rights Reserved Effective 10-1-2007 Part Number 882.00740.00 Bulletin: SC2-615A.4 Page 2 SMC Series Chillers...
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Page 3: Safety Considerations
Safety Considerations Sterling, Inc. SMC Series Chillers are designed to provide safe and reliable operation when installed and operated within design specifications, following national and local safety codes. To avoid possible personnel injury or equipment damage when installing, operating or maintaining this equipment, use good judgment and follow these safe practices: Follow all SAFETY CODES. -
Page 4: Table Of Contents
Table of Contents General Information ... 7 Introduction Necessary Documents Models Covered Available Options Uncrating Your New Chiller In the Event of Shipping Damages If the Shipment is Not Complete If the Shipment is Incorrect Returns Chiller Installation ... 13 Electrical Connections Process Water Connections SMC Condenser Air Supply... - Page 5 Startup Checklists ... 23 Introduction SMC Pre-Startup Checklist SMC Startup Checklist SMC Water Circuit Pressure Drop Table Microprocessor Control... 25 Introduction Setting the Process Water Temperature LED Indicators Temperature Controller Keys Auto-Tuning SMC Series Chillers Optional Communications Optional Graphic Panel... 30 Indicator Lights Switches Routine Maintenance ...
- Page 6 Charts and Figures Figure 1: SMC050 Process Pump Curves... 11 Figure 2: SMC100 Process Pump Curves... 11 Figure 3: PCA150 Process Pump Curves ... 11 Figure 4: SMC Cast Iron Centrifugal Pump Curve 1/3 hp (0.249 kW)... 12 Figure 5: SMC Series Chiller Specifications ... 13 Figure 6: Ethylene Glycol Curve ...
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Page 7: General Information
Introduction Sterling, Inc.'s SMC Series Water Chillers are reliable, accurate, and easy-to-use air cooled chillers designed for use with water/glycol. Standard range of operation is 30°F (-1°C) to 65°F (18°C) for applications using glycol and 45ºF (7ºC) to 65°F (18°C) for water-only applications. -
Page 8: Available Options
Available Options SMC Series Chillers are available with options that tailor the unit to your requirements. Some are factory installed, some can be retrofitted in the field. Consult your local Sterling, Inc. Sales Representative. Some of these options are: Special Pumps Special pump options are available for greater pressure and flow rates. -
Page 9: In The Event Of Shipping Damages
In the Event of Shipping Damages According to the contract terms and conditions of the Carrier, the responsibility of the shipper ends at the time and place of shipment. The Carrier then assumes full responsibility of the shipment. Notify the transportation company's local agent. Hold the damaged goods and packing material for the examining agent's inspection. -
Page 10: Returns
Returns IMPORTANT! Do not return any damaged or incorrect items until you receive shipping instructions from STERLING, Inc. Page 10 SMC Series Chillers... -
Page 11: Figure 1: Smc050 Process Pump Curves
Figure 1: SMC050 Process Pump Curves Figure 2: SMC100 Process Pump Curves Figure 3: SMC150 Process Pump Curves SMC Series Chillers Page 11... -
Page 12: Figure 4: Smc Cast Iron Centrifugal Pump Curve 1/3 Hp (0.249 Kw)
Figure 4: SMC Cast Iron Centrifugal Pump Curve 1/3 hp (0.249 kW) Page 12 SMC Series Chillers... -
Page 13: Figure 5: Smc Series Chiller Specifications
Figure 5: SMC Series Chiller Specifications Optional gauge package Optional gauge package PUMP PRESSURE Mini Chiller PC Series Portable Chiller No Flow indicator HIGH PUMP COMPRESSOR REFRIGERANT REFRIGERANT PRESSURE PRESSURE POWER (for pumpless A0537868 units only) NO FLOW Application Engineering 20"... -
Page 14: Chiller Installation
Electrical Connections Check serial tag voltage and amperage requirements and make sure your electrical service conforms. See Figure 5 on page 13 for total running amps. Bring properly sized power leads and ground from a fused disconnect (installed by your electrician) to the main power terminal in the chiller's electrical enclosure. -
Page 15: Pca Condenser Air Supply
Process Water Bypass All SMC chillers have an internal bypass device (patent pending). If the process flow becomes blocked during chiller operation, this component allows water to flow through the chiller. This protects the chiller from freeze-up, excessive pressures, and pump damage, and allows other safety features to remain effective. -
Page 16: Figure 6: Ethylene Glycol Curve
A corrosion inhibitor suitable for the materials in the system should be added to the glycol/water solution. If straight water use is desired, contact the Sterling, Inc. Engineering Department. The six gallon (23 liter) reservoir is not designed to withstand water pressure above 5 psi (34 kPa). -
Page 17: Overhead Process Considerations
Overhead Process Considerations If your application has chilled water or process piping above the reservoir fill and vent level, install a standpipe to a point 1’ (30 cm) above the highest point in the system. In applications where the process or its piping is 15 feet (4.6 m) or more above the reservoir, you must take steps to prevent over-pressurization of the reservoir. -
Page 18: Sequence Of Operation
• The SMC unit has a leaving water temperature range of 30°F (-1°C) to 65°F (18°C). Do not attempt to run the SMC unit outside this temperature range or damage to the unit may occur. • When operating the SMC unit between 30°F (-1°C) and 40°F (5°C), you must use a solution of 75% water and 25% industrial-grade ethylene glycol with a suitable corrosion inhibitor to protect the SMC unit from freeze-up. -
Page 19: High Pressure Cutout
High Pressure Cutout The high pressure cutout is an electro-mechanical safety feature that opens the control circuit if the system condensing pressure exceeds a safe level. The chiller will automatically restart when the pressure drops back to an acceptable level. Model SMC050 SMC100... -
Page 20: Figure 8: Smc Component Identification
Figure 8: SMC Component Identification Page 20 SMC Series Chillers... -
Page 21: Figure 9: Piping Schematic - 1 Pump With Reservoir
Figure 9: Piping Schematic - 1 Pump with Reservoir Discharge line Refrigeration evacuation valve Refrigeration evacuation valve Suction Line Refrigeration access valve High pressure control pressure control Optional CPR valve Refrigeration Compressor access valve, compressor-mounted Pump SMC Series Chillers Relief valve Filter Expansion... -
Page 22: Figure 10: Piping Schematic - 1 Pump Without Reservoir
Figure 10: Piping Schematic - 1 Pump Without Reservoir Discharge line Refrigeration evacuation valve Refrigeration evacuation valve Suction line Refrigeration access valve High pressure control pressure control Optional CPR valve Refrigeration Compressor access valve, compressor-mounted Pump Page 22 Relief valve Filter Expansion Sight... -
Page 23: Figure 11: Piping Schematic - No Pump, No Reservoir
Figure 11: Piping Schematic - No Pump, No Reservoir Discharge line Refrigeration evacuation valve Refrigeration evacuation valve Suction line Refrigeration access valve High pressure control pressure control Optional CPR valve Refrigeration Compressor access valve, compressor-mounted SMC Series Chillers Relief valve Filter Expansion Sight... -
Page 24: Microprocessor Control
Introduction Follow the check lists below for the startup of your new chiller. These lists assume the installation information elsewhere in this manual has been read and followed. New chillers should be started up and checked by a qualified refrigeration service technician. SMC Pre-Startup Checklist 1. -
Page 25: Smc Water Circuit Pressure Drop Table
SMC Water Circuit Pressure Drop Table Model Gallons per minute SMC050 SMC100 SMC150 SMC Series Chillers ΔP (psig) Liters per minute 13.6 18.1 12.5 13.6 18.1 13.6 18.1 ΔP (kPa) 17.3 27.6 51.8 86.2 17.3 17.3 20.7 34.5 17.3 17.3 20.7 24.2 Page 25... -
Page 26: Microprocessor Control
Introduction Standard SMC Series chillers use a microprocessor-based PID controller. The controller is a modular, self-contained unit that can slide from its mounting housing. It is factory set and adjusted; no field adjustment to the internal controls is necessary. Standard models 30°F to 65°F (-1ºC to 18ºC) Setting the Process Water Temperature To change the process water temperature set point: LED Indicators... -
Page 27: Figure 12: Typical Smc Series E5Ck Microprocessor Controller
Figure 12: Typical SMC Series E5CK Microprocessor Controller OUT1 OUT2 MANU STOP RMT OMRON OUT2 LED The orange energizes whenever the process temperature is two degrees (2°F/ºC) OUT2 or more above the To Process set point. The compressor then comes on and runs until the temperature at the To Process thermocouple is two degrees (2°F/ºC) below the set point. -
Page 28: Temperature Controller Keys
RMT LED The orange AT LED The orange SUB1 LED The orange SUB1 degrees (2°F/ºC) or more below the To Process set point. The compressor then shuts down by means of a latching circuit, and does not run again until the temperature at the To Process thermocouple is two degrees (2°F/ºC) above the set point. -
Page 29: Auto-Tuning Smc Series Chillers
Do not change any of the control settings without consulting the Sterling Service Department. The AEC, Inc. warranty does not cover chiller failures from tampering with controller settings! Down Key Each press of the the values or settings on the Up Key Each press of the the values or settings on the... -
Page 30: 5-6 Optional Communications
5-6 Optional Communications Standard Omron Protocol The communications function allows you to monitor and set E5CK parameters by a program prepared and running on a host computer connected to the E5CK controller. When using the communications function, you must add on the unit for RS-232C or RS-485 communications. -
Page 31: Optional Graphic Panel
Indicator Lights PUMP ON (green) This indicator lights when the pump is running. COMPRESSOR ON (green) This indicator lights when the compressor is operating. HIGH REFRIGERANT PRESSURE (red) This indicator lights if the condensing pressure exceeds a safe level. The chiller goes to Idle mode until the high refrigerant pressure cutout resets. -
Page 32: Figure 13: Optional Graphic Panel
Figure 13: Optional Graphic Panel PC Series Portable Chiller HIGH PUMP COMPRESSOR REFRIGERANT REFRIGERANT PRESSURE PRESSURE POWER E5CS O RO A0537868 Page 32 SMC Series Chillers... -
Page 33: Routine Maintenance
Lubrication Every three months, grease all fan motors and pump motors that do not have permanently sealed bearings. Remove grease relief plug (motors only) before adding grease. Failure to do so may result in dislodging the bearing grease retainer, eventually causing bearing failure. -
Page 34: Figure 15: Typical Smc Wiring Schematic
Figure 15: Typical SMC Wiring Schematic Earth ground Remote interlock by others Control power ON/OFF Jumper 1S-1LT 1 X1 "Low Refrig Pres" 1 10 1CNTL Jumper Type K Thermocouple Page 34 230V 115V "Hi Refrig Pres" Legend Customer wiring/Customer-supplied components Optional components 1MTR Pump... -
Page 35: Figure 16: Smc Wiring Schematic For Chillers With No Pump Or Reservoir
Figure 16: SMC Wiring Schematic for Chillers with No Pump or Reservoir Remote Earth interlock ground by others 230V Control power ON/OFF Jumper 1S-1LT 115V "No Flow" 1FLS 1FLS Jumper 1CNTL Type K thermocouple SMC Series Chillers "Low Refrig "High Refrig Pres"... - Page 36 - Notes - Page 36 SMC Series Chillers...
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Page 37: Troubleshooting Guide
Problem Chiller will not run. Pump runs, compressor cycles at short intervals. The leaving water temperature is too high. Pump pressure is low (see pump curves). Pump pressure is too high. SMC Series Chillers Troubleshooting Guide Cause Check main disconnect No power. - Page 38 Refrigerant high pressure Check for dirty condenser. cutout switch contacts are Check for condenser air open. obstruction. Defective fan motor. Repair or replace. Check for high/low voltage. Must be within plus or Compressor internal minus 10% of the overload is open. Allow nameplate rating.
- Page 39 PCA Unit Parts List Part Number A0537868 SMC Graphic A0537899 BZ Pressure Gauge A0534584 Red Neon Graphic Light * A0534586 Green Neon Graphic Light * A0500857 2” Swivel Casters A0534269 1/16 DIN Digital Temperature Controller A0537955 Process Water Flow Switch A0533873 Thermocouple, 8’...
- Page 40 - Notes - Page 40 SMC Series Chillers...
- Page 41 - Notes - SMC Series Chillers Page 41...
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Page 42: Technical Assistance
-Notes - Technical Assistance Page 42 SMC Series Chillers... -
Page 43: Parts Department
Parts Department Call toll-free 7am - 5pm CST [800] 423-3183 Or call [262] 641-8610, Fax [262] 641-8653 The Parts Department at AEC, Inc. is ready to provide the parts to keep your systems up and running. AEC replacement parts ensure operation at design specifications. Please have the model and serial number of your equipment when you call.
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