Temptek CF Series Instruction Manual
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Temptek CF Series Instruction Manual

Cf series portable chiller 5 - 40 tons air-cooled & water-cooled
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I.O.M. #075 11/05
INSTRUCTION MANUAL
• INSTALLATION • OPERATION • MAINTENANCE
with CF-1 Instrument
TEMPTEK, INC.
525 East Stop 18 Road Greenwood, IN 46142
317-887-0729 fax: 317-881-1277
Service Department fax: 317-885-8683
www.Temptek.com
e-mail: sales@Temptek.com

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  • Page 1 I.O.M. #075 11/05 INSTRUCTION MANUAL • INSTALLATION • OPERATION • MAINTENANCE with CF-1 Instrument TEMPTEK, INC. 525 East Stop 18 Road Greenwood, IN 46142 317-887-0729 fax: 317-881-1277 Service Department fax: 317-885-8683 www.Temptek.com e-mail: sales@Temptek.com...
  • Page 2 Page: 2...
  • Page 3 INSTRUCTION MANUAL CF Series Portable Chiller 5 - 40 Tons Air-Cooled & Water-Cooled COVERING INSTALLATION OPERATION MAINTENANCE TEMPTEK, INC. 525 East Stop 18 Road Greenwood, IN 46142 317-887-0729 fax: 317-881-1277 Service Department fax: 317-885-8683 www.TempTek.com e-mail: sales@TempTek.com...

  • Page 4: Table Of Contents

    CF Series Portable Chillers with CF-1 Instrument TABLE OF CONTENTS GENERAL Introduction Unit location Efficiency Safety Clean air act Miscellaneous INSTALLATION General To and From process connections Water supply connection Air-cooled condenser Water-cooled condenser Electrical connection OPERATIONS General Start up/operations procedure...
  • Page 5 CF Series Portable Chillers with CF-1 Instrument RELATED DRAWINGS Mechanical Schematic : Water-Cooled : 5 - 10 Tons Mechanical Schematic : Water-Cooled : 15 - 40 Tons Mechanical Schematic : Air-Cooled : 5 - 10 Tons Mechanical Schematic : Air-Cooled : 15 - 30 Tons...
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  • Page 7: General

    CF Series Portable Chillers with CF-1 Instrument GENERAL INTRODUCTION UNIT LOCATION EFFICIENCY SAFETY CLEAN AIR ACT MISCELLANEOUS Page: 7 525 East Stop 18 Road Greenwood, Indiana 46142 317-887-6352 Fax: 317-881-1277 Service Department Fax: 317-885-8683 Website: www.Temptek.com Email: service@Temptek.com...

  • Page 8: Introduction

    CF Series Portable Chillers with CF-1 Instrument INTRODUCTION This manual covers portable chillers from 5 to 40 tons. When calling for assistance from the Manufacturer’s Service Department, it is important to know the model and serial number of the particular unit. The model number encodes critical unit information which is helpful in any attempt to troubleshoot operating difficulties.

  • Page 9: Safety

    CF Series Portable Chillers with CF-1 Instrument recommendations followed. The Manufacturer accepts no responsibility for inefficient operation, or damage caused by foreign materials or failure to use adequate water treatment. SAFETY It is important to become thoroughly familiar with this manual and the operating characteristics of the unit.
  • Page 10 CF Series Portable Chillers with CF-1 Instrument Cover Panel Pressure Gauges Instrument Enclosure Panel Electrical Panel Enclosure Air-Cooled. Casters Water-Cooled. Air Discharge Protective Fan Shroud Fan Motor Hot Gas Bypass Valve Refrigerant Site Glass Expansion Valve Liquid Line Solenoid Compressor...
  • Page 11 CF Series Portable Chillers with CF-1 Instrument To Process Connection From Process Connection Reservoir Optional Reservoir Sight Glass Refrigerant Sight Glass Condenser Water-Out Expansion Valve Connection Reservoir Make-Up Compressor Connection Electrical Panel Condenser Water-In Connection (optional) Condenser Condenser Water Regulator Valve...
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  • Page 13: Installation

    CF Series Portable Chillers with CF-1 Instrument INSTALLATION GENERAL TO AND FROM PROCESS CONNECTIONS WATER SUPPLY CONNECTION AIR COOLED CONDENSER INSTALLATION WATER-COOL CONDENSER INSTALLATION ELECTRICAL CONNECTION Page: 13 525 East Stop 18 Road Greenwood, Indiana 46142 317-887-6352 Fax: 317-881-1277 Service Department Fax: 317-885-8683 Website: www.Temptek.com...

  • Page 14: To And From Process Connections

    CF Series Portable Chillers with CF-1 Instrument GENERAL All process piping materials (such as hose, rigid piping, valves or filters) used in process water piping circuitry must be rated for 100°F minimum temperature and 100 PSI minimum pressure. All such materials must have the equivalent or larger diameter of the particular process connection that length of process water piping is connected to.

  • Page 15: Water Supply Connection

    CF Series Portable Chillers with CF-1 Instrument To Process Connection From Process Connection Condenser Water-Out Connection Water Supply Connection Condenser Water-In Connection (with optional water regulator valve) Water-Cooled model shown. WATER SUPPLY CONNECTION The automatic water supply make-up system continually monitors the reservoir tank and fills it when needed.
  • Page 16 CF Series Portable Chillers with CF-1 Instrument Air flow is generated by the motor mounted fans (figure 2.4A) or centrifugal blowers (figure 2.4B). Air flow is from the outside of the chiller, through the condenser and exhausted through the top of the unit.

  • Page 17: Water-Cooled Condenser

    CF Series Portable Chillers with CF-1 Instrument All air cooled units must have all enclosure panels in place before operating compressor. Air will not be drawn through the condenser coil if they are not in place. This will cause the compressor to lockout on the high pressure safety fault.

  • Page 18: Electrical Connection

    CF Series Portable Chillers with CF-1 Instrument ELECTRICAL CONNECTION NEMA 1 MODELS Electrical power supply requirements for Nema 1 units are identified on the equipment data plate. Determine the plant’s voltage supply is the same as the unit’s voltage requirements.
  • Page 19 CF Series Portable Chillers with CF-1 Instrument GENERAL Make certain all ground connections to the unit are properly affixed. Make certain power conductor, disconnecting means, and fusing are properly sized according to the unit’s power supply requirements. INFORMATION REGARDING ‘PHASING’ OF SCROLL...
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  • Page 21: Operations

    CF Series Portable Chillers with CF-1 Instrument OPERATIONS GENERAL START UP/OPERATIONS PROCEDURE INSTRUMENT SHUT DOWN Page: 21 525 East Stop 18 Road Greenwood, Indiana 46142 317-887-6352 Fax: 317-881-1277 Service Department Fax: 317-885-8683 Website: www.Temptek.com Email: service@Temptek.com...
  • Page 22 CF Series Portable Chillers with CF-1 Instrument GENERAL Failure to follow the factory required operations procedure may adversely affect the unit’s ability to adequately control process temperature and may create a hazardous operating condition which may result in serious operator injury and/or unit damage.

  • Page 23: Start Up/Operations Procedure

    CF Series Portable Chillers with CF-1 Instrument START UP / OPERATION PROCEDURE SYSTEM FILL The unit has an internal reservoir which must be filled and maintained for proper operation. The unit has a level switch mounted at the proper water level in the reservoir.
  • Page 24 CF Series Portable Chillers with CF-1 Instrument setpoint to 70°F to prevent the compressor from activating during this procedure. Remove all necessary cover panels to access the pump motor. Note that the electrical power is engaged at this point and caution must be observed while the electrical supply is engaged and cabinet panels are removed and opened.
  • Page 25 CF Series Portable Chillers with CF-1 Instrument If the unit is phased incorrectly, the operator must: Disengage the electrical power supply to the unit at the unit’s disconnect switch. Follow proper lockout procedures before proceeding. Once the electrical power supply is disengaged, reverse any two power leads of the power cord at the disconnect terminals.

  • Page 26: Instrument/Operation

    CF Series Portable Chillers with CF-1 Instrument process circuitry. This will allow a portion of the flow to bypass the process and return directly to the chiller. This keeps the total flow above the cutoff point. Figure 3.2E illustrates a typical bypass loop.
  • Page 27 CF Series Portable Chillers with CF-1 Instrument PRECAUTIONS: The chiller control is programmed from the factory with a setpoint range of 48° to 90°F. To operate below 48°F, the addition of inhibited propylene glycol and modification of the safety control settings are required. Diligent monitoring of the water/glycol solution is mandatory to prevent freezing of the evaporator.
  • Page 28 CF Series Portable Chillers with CF-1 Instrument Under normal conditions (no fault conditions, compressor has been off for three minutes) the instrument will turn on the compressor when the To Process temperature is above the setpoint. The instrument will turn on the hot gas bypass when the To Process temperature is below the setpoint by no more than 3 degrees.
  • Page 29 CF Series Portable Chillers with CF-1 Instrument STATUS LIGHTS COMPRESSOR: illuminates when compressor is turned on. CAPACITY CONTROL: illuminates when capacity control system is turned on. REFRIGERANT FAULT: illuminates when there is a high pressure or low pressure alarm. Check troubleshooting section of this manual for more details.

  • Page 30: Shut Down Procedure

    CF Series Portable Chillers with CF-1 Instrument critical to equipment efficiency. Head pressure on water condensed units will vary with ambient temperatures between 190-290 psig. LOW PRESSURE GAUGE: indicates refrigerant pressure on the suction side of the compressor. This pressure will fluctuate with the process temperature.

  • Page 31: Troubleshooting

    CF Series Portable Chillers with CF-1 Instrument TROUBLESHOOTING UNIT WILL NOT START COMPRESSOR HUMS BUT WILL NOT START SHUTS OFF ON HIGH PRESSURE SHUTS OFF ON LOW PRESSURE COMPRESSOR SHUTS OFF ON INTERNAL OVERLOAD LOW OR NO PROCESS PRESSURE OR WATER FLOW...

  • Page 32: Unit Will Not Start

    CF Series Portable Chillers with CF-1 Instrument UNIT WILL NOT START Power off. Check main disconnect. Main line open. Check fuses. Loose terminals. Tighten terminals with POWER OFF. Control circuit open. check control voltage fuses and transformer. COMPRESSOR HUMS BUT WILL NOT START Contactor.

  • Page 33: Shuts Off On Low Pressure

    CF Series Portable Chillers with CF-1 Instrument temperature*. If valve is defective, have valve repaired or * See Temperature-Pressure chart in Section 8.5 for replaced by a refrigeration serviceman. refrigerant pressure. Insufficient condenser water flow. Check condenser water pumping system.

  • Page 34: Compressor Shuts Off On Internal Overload

    CF Series Portable Chillers with CF-1 Instrument Improperly set low pressure switch. Have a refrigeration serviceman reset control or replace if defective. Restriction in the liquid line. Clogged filter drier. Check for pressure or temperature drop and have drier core replaced by a refrigeration serviceman.

  • Page 35: Sensor

    CF Series Portable Chillers with CF-1 Instrument Expansion valve plugged or inoperative. Check thermal bulb and capillary tube for damage. Have repaired or replaced if defective by a refrigeration serviceman. Plugged filter. Check filter in chilled water circuit and clean.
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  • Page 37: Maintenance

    CF Series Portable Chillers with CF-1 Instrument MAINTENANCE WARRANTY SERVICE PROCEDURE PERIODIC PREVENTATIVE MAINTENANCE SPECIAL MAINTENANCE SOLENOID VALVE SERVICE PUMP SEAL SERVICE CHECKING THE REFRIGERANT CHARGE PROPER CLEANING PROCEDURE FOR BRAZED PLATE EVAPORATOR Page: 37 525 East Stop 18 Road Greenwood, Indiana 46142...

  • Page 38: Warranty Service Procedure

    CF Series Portable Chillers with CF-1 Instrument WARRANTY SERVICE PROCEDURE In the event of a problem with a chiller that can not be resolved by normal troubleshooting procedures, the customer is invited to consult the Service Department for assistance. The correct model number and serial number of the chiller must be available.

  • Page 39: Special Maintenance

    CF Series Portable Chillers with CF-1 Instrument Refrigerant sight glass: check for bubbles when compressor is operating at 100%. Check the moisture indicator for a color other than green. Clean unit. SPECIAL MAINTENANCE Any service of the refrigeration system must be accomplished by a certified refrigeration technician.

  • Page 40: Solenoid Valve Service

    CF Series Portable Chillers with CF-1 Instrument SOLENOID VALVE SERVICE Units with the optional water make-up system use a solenoid valve (figure 5.4A) to regulate flow into the reservoir tank. The solenoid valve is controlled by the float switch. Generally, solenoid valves fail due to poor water quality, low water flow, or defective valve elements.
  • Page 41 CF Series Portable Chillers with CF-1 Instrument Identify the mesh screen. Plunger Diaphragm assembly Gently removed the mesh screen and clean or replace as necessary. Clean the valve body. Reset the mesh screen into the valve body. If a new diaphragm...

  • Page 42: Pump Seal Service

    CF Series Portable Chillers with CF-1 Instrument PUMP SEAL SERVICE Tension Spring Rotating Member The coolant pump seal is a carbon/niresist shaft seal assembly including a stationary member, rotating member and tension spring (figure 5.5A). The operator can Figure 5.5A...
  • Page 43 CF Series Portable Chillers with CF-1 Instrument removed from the motor housing (figure 5.5C). Locate and remove the pump casing bolts. These bolts secure the motor and motor adapter to the pump casing (figure 5.5D). Separate the motor and motor adapter from the Typical pump casing bolt Figure 5.5D...
  • Page 44 CF Series Portable Chillers with CF-1 Instrument Install new stationary seal member in pump casing cavity (figure 5.5I). The operator must be certain the stationary seal member is fully squared and seated in cavity. Slide the rotating member onto lubricated pump shaft (figure 5.5J).

  • Page 45: Checking The Refrigerant Charge

    CF Series Portable Chillers with CF-1 Instrument CHECKING THE REFRIGERANT CHARGE All standard chillers are manufactured with thermostatic expansion valves as the metering device to the evaporator. All standard chillers have a refrigerant sight glass (figure 5.6A) with a moisture indicator. To check...
  • Page 46 CF Series Portable Chillers with CF-1 Instrument To begin, remove the piping to the “water in” port at the evaporator. Remove any solids that have collected at this point. Then back flush the evaporator to remove any solids that may be trapped between the plates (see back flush procedure below).

  • Page 47: Components

    CF Series Portable Chillers with CF-1 Instrument COMPONENTS WATER SYSTEM REFRIGERATION SYSTEM Page: 47 525 East Stop 18 Road Greenwood, Indiana 46142 317-887-6352 Fax: 317-881-1277 Service Department Fax: 317-885-8683 Website: www.Temptek.com Email: service@Temptek.com...

  • Page 48: Water System

    CF Series Portable Chillers with CF-1 Instrument WATER SYSTEM MOTOR/PUMP ASSEMBLY: the motor/pump assembly circulates chilled fluid to the process loop. The pump assembly is built of total stainless steel to maintain water quality (figure 6.1A). REFRIGERATION SYSTEM COMPRESSOR: hermetic or semi- Pump Motor Assembly Figure 6.1A...
  • Page 49 CF Series Portable Chillers with CF-1 Instrument element is chartreuse or yellow, the system has been contaminated with moisture. In such case, the filter-drier must be replaced. The replacement of the filter-drier must be completed by a qualified refrigerant service technician (figure 6.2D).
  • Page 50 CF Series Portable Chillers with CF-1 Instrument Liquid receiver: located after the condenser, this component receives and stores liquid refrigerant leaving the condenser. Service valves: have been provided throughout the system. Only a qualified refrigeration service technician shall operate these valves.

  • Page 51: Related Drawings

    CF Series Portable Chillers with CF-1 Instrument RELATED DRAWINGS MECHANICAL SCHEMATIC : WATER-COOLED : 2 - 10 TONS MECHANICAL SCHEMATIC : WATER-COOLED : 15 - 40 TONS MECHANICAL SCHEMATIC : AIR-COOLED : 5 - 10 TONS MECHANICAL SCHEMATIC : AIR-COOLED : 15 - 30 TONS...
  • Page 52 CF Series Portable Chillers with CF-1 Instrument MECHANICAL SCHEMATIC : WATER-COOLED : 2 - 10 TONS Page: 52 525 East Stop 18 Road Greenwood, Indiana 46142 317-887-6352 Fax: 317-881-1277 Service Department Fax: 317-885-8683 Website: www.Temptek.com Email: service@Temptek.com...
  • Page 53 CF Series Portable Chillers with CF-1 Instrument MECHANICAL SCHEMATIC : WATER-COOLED : 15 - 40 TONS Page: 53 525 East Stop 18 Road Greenwood, Indiana 46142 317-887-6352 Fax: 317-881-1277 Service Department Fax: 317-885-8683 Website: www.Temptek.com Email: service@Temptek.com...
  • Page 54 CF Series Portable Chillers with CF-1 Instrument MECHANICAL SCHEMATIC : AIR-COOLED : 2 - 10 TON MODELS Page: 54 525 East Stop 18 Road Greenwood, Indiana 46142 317-887-6352 Fax: 317-881-1277 Service Department Fax: 317-885-8683 Website: www.Temptek.com Email: service@Temptek.com...
  • Page 55 CF Series Portable Chillers with CF-1 Instrument MECHANICAL SCHEMATIC : AIR-COOLED : 15 - 30 TON MODELS Page: 55 525 East Stop 18 Road Greenwood, Indiana 46142 317-887-6352 Fax: 317-881-1277 Service Department Fax: 317-885-8683 Website: www.Temptek.com Email: service@Temptek.com...
  • Page 56 CF Series Portable Chillers with CF-1 Instrument TYPICAL ELECTRICAL SCHEMATIC : AIR-COOLED MODELS POWER ENTRY GROUND 1 MOL PUMP COMPRESSOR FAN MOTOR FAN MOTOR UNIT (OPTIONAL) TRANSFORMER ON/OFF 110VAC SEC. GROUND SNUBBER POWER ON LEVEL SWITCH WATER MAKE-UP SOLENOID (OPTIONAL)
  • Page 57 CF Series Portable Chillers with CF-1 Instrument TYPICAL ELECTRICAL SCHEMATIC : WATER-COOLED MODELS POWER ENTRY GROUND 1 MOL PUMP COMPRESSOR UNIT TRANSFORMER ON/OFF 110VAC SEC. GROUND SNUBBER POWER ON LEVEL SWITCH WATER MAKE-UP SOLENOID (OPTIONAL) ANTI-DRAIN BACK SOLENOID (OPTIONAL) 1 MOL...
  • Page 58 CF Series Portable Chillers with CF-1 Instrument PHYSICAL SCHEMATIC : AIR-COOLED : 7.5 - 10 TONS Page: 58 525 East Stop 18 Road Greenwood, Indiana 46142 317-887-6352 Fax: 317-881-1277 Service Department Fax: 317-885-8683 Website: www.Temptek.com Email: service@Temptek.com...
  • Page 59 CF Series Portable Chillers with CF-1 Instrument PHYSICAL SCHEMATIC : AIR-COOLED : 5 TONS Page: 59 525 East Stop 18 Road Greenwood, Indiana 46142 317-887-6352 Fax: 317-881-1277 Service Department Fax: 317-885-8683 Website: www.Temptek.com Email: service@Temptek.com...
  • Page 60 CF Series Portable Chillers with CF-1 Instrument PHYSICAL SCHEMATIC : WATER-COOLED Page: 60 525 East Stop 18 Road Greenwood, Indiana 46142 317-887-6352 Fax: 317-881-1277 Service Department Fax: 317-885-8683 Website: www.Temptek.com Email: service@Temptek.com...
  • Page 61 CF Series Portable Chillers with CF-1 Instrument 7.10 DUCT SCHEMATIC FOR AIR-COOLED CHILLERS For models equiped with centrifugal blower. Models with equipped with fans can not be ducted. NOTE: THIS DRAWING IS FOR EXPLANATION PURPOSES ONLY, NOT FOR CONSTRUCTION PURPOSES...
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  • Page 63 CF Series Portable Chillers with CF-1 Instrument APPENDIX OPERATIONS BELOW 48°F WATER QUALITY CONTROL INHIBITED PROPYLENE GLYCOL SENSOR CURRENT VS TEMPERATURE CHART REFRIGERANT PRESSURE-TEMPERATURE CHART CHILLER CAPACITY AND DERATE CHART Page: 63 525 East Stop 18 Road Greenwood, Indiana 46142...
  • Page 64 CF Series Portable Chillers with CF-1 Instrument OPERATIONS BELOW 48°F Chillers supplied with the automatic water supply system, the water supply connection must be plugged when operating below 48°F or anytime the system utilizes a water/inhibited propylene glycol solution. The system must be manually filled and the mix shall be checked for the proper ratio on a regular basis.
  • Page 65 CF Series Portable Chillers with CF-1 Instrument WATER QUALITY CONTROL Lack of proper water treatment can damage the chilling unit. The services of a competent water treatment specialist should be obtained and their recommendations followed. It is the equipment owner’s responsibility to prevent damage from foreign material or inadequate water treatment.
  • Page 66 CF Series Portable Chillers with CF-1 Instrument REFRIGERANT PRESSURE-TEMPERATURE CHART Page: 66 525 East Stop 18 Road Greenwood, Indiana 46142 317-887-6352 Fax: 317-881-1277 Service Department Fax: 317-885-8683 Website: www.Temptek.com Email: service@Temptek.com...
  • Page 67 CF Series Portable Chillers with CF-1 Instrument CHILLER CAPACITY AND DERATE CHART Standard chiller rating is at 50°F. For all other temperature settings, output tonnage is altered as follows: OUTPUT FULL TEMPERATURE AVAILABLE % °F CAPACITY 105% 100% NOTES: If operation of the chiller at less than 48°F is required, an inhibited propylene glycol solution is required.
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  • Page 69 © 2009 TEMPTEK, INC. RE 2 09/09...

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