Sterling A0554831 User Manual

2-40 hp portable chillers
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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 are subject to change without notice.
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2–40 hp Portable Chillers
Part Number: A0554831
Bulletin Number: SC2-610C.10
Effective: 4/3/2008
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Summary of Contents for Sterling A0554831

  • Page 1 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: _________________________ _________________________ _________________________ _________________________ _________________________ _________________________ 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.
  • Page 2 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.
  • Page 3: Table Of Contents

    Table of Contents CHAPTER 1: SAFETY ..............6 How to Use This Manual ..................... 6 Safety Symbols Used in this Manual ..............6 Warnings and Precautions ..................7 Responsibility ......................7 CHAPTER 2: FUNCTIONAL DESCRIPTION....... 8 Models Covered in This Manual.................. 8 General Description.....................
  • Page 4 3-11 Initial Start-Up......................28 CHAPTER 4: OPERATION ............29 Panel Buttons, Indicator Lights, and Switches ............29 Microprocessor Controllers..................29 Graphic Panel......................32 Start-up........................35 Setting the Process Water Temperatures ..............35 Auto-Tuning....................... 35 Optional Communications ..................35 Programming the Electronic High/Low Thermostat........... 36 CHAPTER 5: MAINTENANCE ...........
  • Page 5 Flow and Pressure Considerations..............61 Recirculation Pump Specifications ..............61 Remote Air-Cooled Chiller Configurations ..............62 Typical Ductwork for Air-Cooled Chillers..............63 Piping Diagrams ......................64 Central and Gravity Return Piping with Standpipe Diagram........64 Typical Piping Schematic, 2 and 3 1/2 hp Models..........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 through 40 hp, No-Pump Models ......68...
  • Page 6: Chapter 1: Safety

    Chapter 1: Safety 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.
  • Page 7: Warnings And Precautions

    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.
  • Page 8: Chapter 2: Functional Description

    Chapter 2: Functional Description 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.
  • Page 9: General Description

    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...
  • Page 10: Standard Features

    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.
  • Page 11: Electrical Features

    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 •...
  • Page 12: Safety Devices And Interlocks

    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.
  • Page 13: Low Pressure Cutout

    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.
  • Page 14: Optional Features

    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.
  • Page 15 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.
  • Page 16 Figure 1: Optional Pump Amperages Voltage Construction Full Load Amps 208-230/1/60 Bronze Turbine 12.7 460/3/60 Bronze Turbine 13.2 19.0 Dual SS 2-40 HP Portable Chillers Chapter 2: Functional Description 16 of 70...
  • Page 17: Chapter 3: Installation

    Chapter 3: Installation 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.
  • Page 18: Process Water Connections

    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.
  • Page 19: Condenser Considerations

    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.
  • Page 20: Remote Air-Cooled Chiller Condensers

    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.
  • Page 21 System Configuration. The system can be configured in any of the arrangements shown on 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.
  • Page 22 Figure 2: Equivalent Length in Feet for Valves and 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” 5/8” 7/8” 1 1/8” 1 3/8” 1 5/8’ 2 1/8”...
  • Page 23 Refrigerant Charge Determination. The 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.
  • Page 24: Checking Motor Direction

    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.
  • Page 25: Water Reservoir

    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.
  • Page 26 Figure 6: Ethylene Glycol and Propylene Glycol Curves Pe rce n t G lyc o l Cu rves fo r F ree ze P ro tec tion 40.0 30.0 Eth ylene G lycol 20.0 P rop ylene G lyc ol 10.0 -10.0 -20.0...
  • Page 27: Automatic Water Make-Up Option

    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.
  • Page 28: Initial Start-Up

    3-11 Initial Start-Up • 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. •...
  • Page 29: Chapter 4: Operation

    Chapter 4: Operation 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 is 30ºF to 65ºF (-1ºC to 18ºC).
  • Page 30 Indicator Name Description SUB 1 LED The orange SUB1 LED lights when the process temperature is three degrees or more below the “To Process” setpoint. The compressor then shuts SUB1 down by means of a latching circuit, and it does not run again until the temperature at the “To Process”...
  • Page 31 Figure 7: Typical Portable Chiller Microprocessor Controllers OUT1 OUT2 MANU STOP RMT SUB1 E5CK OMRON 2-40 HP Portable Chillers Chapter 4: Operation 31 of 70...
  • Page 32: Graphic Panel

    Graphic Panel (See Figure 8) Indicator Name Description Compressor On The Compressor On light turns on whenever the Light compressor is operating. Low Temperature The Low Temperature light comes on if the process Light water/glycol temperature drops below the High/Low thermostat set point.
  • Page 33 Indicator Name Description Low Water The Low Water Flow/Pressure light comes on when Flow/Pressure the flow switch (pressure switch on 2 & 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.
  • Page 34 Figure 8: Typical Graphic Panels (With E5CK Controller) COMPRESSOR TEMPERATURE HOT GAS HIGH BY-PASS TEMPERATURE PUMP ON HIGH DISCHARGE TEMPERATURE PUMP HIGH REFRIGERANT OVERLOAD PRESSURE OUT1 LOW WATER LOW REFRIGERANT OUT2 MANU STOP RMT SUB1 FLOW/PRESSURE PRESSURE OMRON E5CK LOW OIL PRESSURE CONTROL ALARM...
  • Page 35: Start-Up

    Start-up 1. Turn on the chiller and put it under a process load. 2. Set the 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.
  • Page 36: Programming The Electronic High/Low Thermostat

    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”...
  • Page 37 Perform the 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. Factory set to F. Use the Up Arrow and Down Arrow keys to toggle between Fahrenheit and Celsius. Stage 1: Freeze Protection 2.
  • Page 38: Chapter 5: Maintenance

    Chapter 5: Maintenance 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 seal, eventually causing bearing failure.
  • Page 39: Maintaining The Condenser

    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-Cooled Chillers Proper water treatment will greatly reduce cleaning intervals.
  • Page 40: Preventative Maintenance Service

    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 can be tailored to fit your maintenance requirements. These inspections include, but are not limited to: •...
  • Page 41: Chapter 6: Troubleshooting

    Chapter 6: Troubleshooting Problem Possible cause Solution Check main disconnect, fuses, wiring, No power. and power lead to unit. Voltage must be within plus or minus Wrong voltage supplied to unit. 10% of nameplate rating. Defective on/off switch. Replace. Replace control circuit fuse. Unit does not run.
  • Page 42 Problem Possible cause Solution Plugged Y-Strainer Clean Pump runs, compressor cycles at Replace relay board on control bed hot Hot gas not coming on short intervals. gas coil Install bypass between to-and-from Low water flow process line Make sure that the water/glycol mixture Water/glycol mixture inadequate protection is right for the process.
  • Page 43: Chapter 7: Appendix

    Chapter 7: Appendix Returned Material Policy Credit Returns Prior to the return of any material, authorization must be given by the manufacturer. A RMS number will be assigned for the equipment to be returned. Reason for requesting the return must be given. All returned material purchased from the manufacturer is subject to 15% ($75.00 minimum) restocking charge.
  • Page 44: Technical Assistance

    Technical Assistance Parts Department Call toll-free 7am–5pm CST [ 800 ] 423-3813 or call [262] 641-8610, Fax [262] 641-8653 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.
  • Page 45: Drawings And Specifications

    Drawings and Specifications 2 hp and 3 1/2 hp Air-Cooled Portable Chillers Nominal operating parameters for air-cooled models are 50ºF (10ºC) leaving water temperature at 2.4 gpm per ton (9.1 lpm per 3.517 kW) with 95ºF (35ºC) ambient air. For 50 Hz applications, multiply capacity by 0.83. Nominal 60 Hz capacity flow rate must be maintained.
  • Page 46: Hp And 7.5 Hp Air-Cooled Portable Chillers

    5 hp and 7.5 hp Air-Cooled Portable Chillers Nominal operating parameters for air-cooled models are 50ºF (10ºC) leaving water temperature at 2.4 gpm per ton (9.1 lpm per 3.517 kW) with 95ºF (35ºC) ambient air. For 50 Hz applications, multiply capacity by 0.83.
  • Page 47: Hp And 15 Hp Air-Cooled Portable Chillers

    10 hp and 15 hp Air-Cooled Portable Chillers Nominal operating parameters for air-cooled models are 50ºF (10ºC) leaving water temperature at 2.4 gpm per ton (9.1 lpm per 3.517 kW) with 95ºF (35ºC) ambient air. For 50 Hz applications, multiply capacity by 0.83. Nominal 60 Hz capacity flow rate must be maintained.
  • Page 48: Hp, 25 Hp, And 30 Hp Air-Cooled Portable Chillers

    20 hp, 25 hp, and 30 hp Air-Cooled Portable Chillers Nominal operating parameters for air-cooled models are 50ºF (10ºC) leaving water temperature at 2.4 gpm per ton (9.1 lpm per 3.517 kW) with 95ºF (35ºC) ambient air. For 50 Hz applications, multiply capacity by 0.83. Nominal 60 Hz capacity flow rate must be maintained.
  • Page 49: Hp And 3.5 Hp Water-Cooled Portable Chillers

    2 hp and 3.5 hp Water-Cooled Portable Chillers Nominal operating parameters for water-cooled models are 50ºF (10ºC) leaving water temperature at 2.4 gpm per ton (9.1 lpm per 3.517 kW) with 85ºF (29ºC) tower water. For 50 Hz applications, multiply capacity by 0.83. Nominal 60 Hz capacity flow rate must be maintained.
  • Page 50: Hp And 7.5 Hp Water-Cooled Portable Chillers

    5 hp and 7.5 hp Water-Cooled Portable Chillers Nominal operating parameters for water-cooled models are 50ºF (10ºC) leaving water temperature at 2.4 gpm per ton (9.1 lpm per 3.517 kW) with 85ºF (29ºC) tower water. For 50 Hz applications, multiply capacity by 0.83. Nominal 60 Hz capacity flow rate must be maintained.
  • Page 51: Hp And 15 Hp Water-Cooled Portable Chillers

    10 hp and 15 hp Water-Cooled Portable Chillers Nominal operating parameters for water-cooled models are 50ºF (10ºC) leaving water temperature at 2.4 gpm per ton (9.1 lpm per 3.517 kW) with 85ºF (29ºC) tower water. For 50 Hz applications, multiply capacity by 0.83. Nominal 60 Hz capacity flow rate must be maintained.
  • Page 52: Hp, 25 Hp, And 30 Hp Water-Cooled Portable Chillers

    20 hp, 25 hp, and 30 hp Water-Cooled Portable Chillers Nominal operating parameters for water-cooled models are 50ºF (10ºC) leaving water temperature at 2.4 gpm per ton (9.1 lpm per 3.517 kW) with 85ºF (29ºC) tower water. For 50 Hz applications, multiply capacity by 0.83. Nominal 60 Hz capacity flow rate must be maintained.
  • Page 53: Hp And 40 Hp Water-Cooled Portable Chillers

    40 hp Water-Cooled Portable Chillers Nominal operating parameters for water-cooled models are 50ºF (10ºC) leaving water temperature at 2.4 gpm per ton (9.1 lpm per 3.517 kW) with 85ºF (29ºC) tower water. For 50 Hz applications, multiply capacity by 0.83. Nominal 60 Hz capacity flow rate must be maintained.
  • Page 54: Hp And 7.5 Hp Remote Air-Cooled Portable Chillers

    5 hp and 7.5 hp Remote Air-Cooled Portable Chillers Nominal operating parameters for remote air-cooled models are 50ºF (10ºC) leaving water temperature at 2.4 gpm per ton (9.1 lpm per 3.517 kW) with 95ºF (35ºC) ambient air. For 50 Hz applications, multiply capacity by 0.83. Nominal 60 Hz capacity flow rate must be maintained.
  • Page 55: Hp And 15 Hp Remote Air-Cooled Portable Chillers

    10 hp and 15 hp Remote Air-Cooled Portable Chillers Nominal operating parameters for remote air-cooled models are 50ºF (10ºC) leaving water temperature at 2.4 gpm per ton (9.1 lpm per 3.517 kW) with 95ºF (35ºC) ambient air. For 50 Hz applications, multiply capacity by 0.83. Nominal 60 Hz capacity flow rate must be maintained.
  • Page 56: Hp Through 40 Hp Remote Air-Cooled Portable Chillers

    20 hp through 40 hp Remote Air-Cooled Portable Chillers Nominal operating parameters for remote air-cooled models are 50ºF (10ºC) leaving water temperature at 2.4 gpm per ton (9.1 lpm per 3.517 kW) with 95ºF (35ºC) ambient air. For 50 Hz applications, multiply capacity by 0.83. Nominal 60 Hz capacity flow rate must be maintained.
  • Page 57: Remote Condenser Assembly Models

    Remote Condenser Assembly Models To convert inches to cm, multiply dimension by 2.54. Fan(s) Remote Condenser Refrigeration Each Totals Overall Dimensions Connections Charge HP Dia. Motor Amps Length Width Height Mtg. Discharge Liquid R-22 flow 460V Fans cfm lbs. ‘A’(in.) ‘B’(in) ‘C’(in.) ‘D’(in) ODS(in.) ODS(in.) lbs.
  • Page 58: Pump Curves, Flow, And Pressure Considerations

    Pump Curves, Flow, and Pressure Considerations 60 Hertz Pump Curves DWG. No. A0554823 2-40 HP Portable Chillers Chapter 7: Appendix 58 of 70...
  • Page 59: Hertz Pump Curves

    50 Hertz Pump Curves DWG. No. S0554823 2-40 HP Portable Chillers Chapter 7: Appendix 59 of 70...
  • Page 60: Hertz Pump Curves

    Evaporator 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 ΔP, psig and kPa 2 HP 3.5 HP...
  • Page 61: Water Pressure Drop Tables

    Evaporator Flow and Pressure Considerations Design Δ P Model Design flow Standard pump power To Process pressure psig bars -A, 2 hp 17.5 30.4 0.746 34.1 235.3 -A, 3.5 hp 29.9 33.7 0.746 33.0 227.5 -A, -R, 5 hp 11.6 43.8 13.7 0.746...
  • Page 62: Remote Air-Cooled Chiller Configurations

    Remote Air-Cooled Chiller Configurations 2-40 HP Portable Chillers Chapter 7: Appendix 62 of 70...
  • Page 63: Typical Ductwork For Air-Cooled Chillers

    Typical Ductwork for Air-Cooled Chillers *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.
  • Page 64: Piping Diagrams

    Piping Diagrams Central and Gravity Return Piping with Standpipe Diagram 2-40 HP Portable Chillers Chapter 7: Appendix 64 of 70...
  • Page 65: Typical Piping Schematic, 2 And 3 1/2 Hp Models

    Typical Piping Schematic, 2 and 3 1/2 hp Models 2-40 HP Portable Chillers Chapter 7: Appendix 65 of 70...
  • Page 66: Typical Piping Schematic, 5 Hp Through 40 Hp, One-Pump Models

    Typical Piping Schematic, 5 hp through 40 hp, One-Pump Models 2-40 HP Portable Chillers Chapter 7: Appendix 66 of 70...
  • Page 67: Typical Piping Schematic, 5 Hp Through 40 Hp, Two-Pump Models

    Typical Piping Schematic, 5 hp through 40 hp, Two-Pump Models 2-40 HP Portable Chillers Chapter 7: Appendix 67 of 70...
  • Page 68: Typical Piping Schematic, 5 Hp Through 40 Hp, No-Pump Models

    Typical Piping Schematic, 5 hp through 40 hp, No-Pump Models 2-40 HP Portable Chillers Chapter 7: Appendix 68 of 70...
  • Page 69: Typical Piping Schematic, 5 Hp Through 40 Hp, One-Pump Models

    Typical Piping Schematic, 5 hp through 40 hp, One-Pump Models 2-40 HP Portable Chillers Chapter 7: Appendix 69 of 70...
  • Page 70: Electrical Schematics

    Electrical Schematics Typical Electrical Subpanel Please refer to your owner’s information packet for more details regarding your specific unit. 2-40 HP Portable Chillers Chapter 7: Appendix 70 of 70 DWG: A0562434...

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