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HP A0554832 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.
DCN No. ____________
© Copyright 2004
All rights reserved.
2–40 hp Portable Chillers
Part Number: A0554832
Bulletin Number: SC2-610C.8
Effective: 11/01/03
_________________________
_________________________
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Table of Contents
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  Summary of Contents for HP A0554832

  • Page 1 2–40 hp Portable Chillers 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.
  • Page 2 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 1 (800) 783-7835; for all other countries, call (414) 354-0970. Have the order number and item number available.
  • Page 3: Table Of Contents

    Condenser Considerations... 19 Water-Cooled Chiller Condensers...19 Air-Cooled Chiller Condensers ...19 Remote Air-Cooled Chiller Condensers ...20 Checking Motor Direction ... 24 Three-Phase Compressors ...24 Water Pumps...24 Condenser Fan...24 Water Reservoir ... 25 3-10 Automatic Water Make-Up Option... 27 2-40 HP Portable Chillers...
  • Page 4 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 Chillers ...51...
  • Page 5 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 Typical Piping Schematic, 5 hp through 40 hp, One-Pump Models ...69...
  • Page 6: Chapter 1: Safety

    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...
  • Page 7: Warnings And Precautions

    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...
  • Page 8: Chapter 2: Functional Description

    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...
  • Page 9: General Description

    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.
  • Page 10: Standard Features

    –20ºF (-29ºC) via pressure-actuated fan staging and a variable-speed primary fan. Reservoir. 2 hp and 3 1/2 hp models use a 6 gallon polyethylene tank. 5 hp and 7.5 hp models use a 20 gallon polyethylene tank. 10 hp and 15 hp models use a 40 gallon polyethylene tank.
  • Page 11: Electrical Features

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

    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.
  • Page 13: Low Pressure Cutout

    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.
  • Page 14: Optional Features

    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.
  • Page 15 Stainless Steel Reservoir. 5 hp to 30 hp models only (Standard on 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 •...
  • Page 16 Figure 1: Optional Pump Amperages Voltage Construction 208-230/1/60 Bronze Turbine 460/3/60 Bronze Turbine Dual SS 2-40 HP Portable Chillers Chapter 2: Functional Description Full Load Amps 12.7 13.2 19.0 16 of 78...
  • 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

    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...
  • Page 19: Condenser Considerations

    For entering air temperatures below 60ºF, an optional fan motor speed control is available. We recommend maintaining a minimum 60ºF ambient temperature. 2-40 HP Portable Chillers Chapter 3: Installation 19 of 78...
  • Page 20: Remote Air-Cooled Chiller Condensers

    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...
  • Page 21 1/2” for every 10 feet. This will allow oil to flow towards the condenser. Discharge 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...
  • Page 22 Eqiv. FT 5 hp 1 1/8 1 1/8 1 1/8 1 1/8 1 1/8 1 1/8 2-40 HP Portable Chillers Globe Valve Angle Valve Equivalent Ft Equivalent Ft 30 – 65°F Leaving Water Temperature Liquid Line Size (O.D.”) 7.5 hp...
  • Page 23 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 Field Installed Piping Charge Lbs. of Pipe O.D.
  • Page 24: Checking Motor Direction

    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...
  • Page 25: Water 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...
  • Page 26 Example: 45°F set point minus 20°F = 25°F. From Figure 28, 25°F equates to 10% by volume of glycol required. 2-40 HP Portable Chillers Pe rce n t G lyc o l Cu rves fo r F ree ze P ro tec tion 20.0...
  • Page 27: Automatic Water Make-Up Option

    To prevent system freeze-up in automatic make-up applications, we recommend using either a chemical 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...
  • Page 28: Initial Start-Up

    (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 is applied. It should be on for at least 24 hours before startup to force dissolved refrigerant from the compressor oil.
  • Page 29: Chapter 4: Operation

    MANU Stop LED STOP RMT LED AT LED 2-40 HP Portable Chillers Description During normal operation, the large red PV LED on the controller displays the actual process temperature at the “To Process” thermocouple. It also lists parameter symbols during setup and...
  • Page 30 8.8.8.8 Index Key Up Arrow Key Down Arrow Key Enter Key 2-40 HP Portable Chillers Description 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...
  • Page 31 Figure 7: Typical Portable Chiller Microprocessor Controllers OUT1 OUT2 MANU STOP RMT OMRON 2-40 HP Portable Chillers SUB1 E5CK Chapter 4: Operation °F °C 2 0 0 0 MADE IN U.S.A. 31 of 78...
  • Page 32: Graphic Panel

    Temperature Light Pump Overload Light High Refrigerant Pressure Light 2-40 HP Portable Chillers Description The Compressor On light turns on whenever the compressor is operating. The Low Temperature light comes on if the process water/glycol temperature drops below the High/Low thermostat set point.
  • Page 33 2-40 HP Portable Chillers Description The Low Water Flow/Pressure light comes on when the flow switch (pressure switch on 2 & 3 hp 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) OUT1 OUT2 MANU STOP RMT OMRON A0554705 (With Sterlco 2000 Controller) 2 0 0 0 MADE IN U.S.A. A0554705 2-40 HP Portable Chillers COMPRESSOR HOT GAS BY-PASS PUMP ON OVERLOAD LOW WATER SUB1 FLOW/PRESSURE E5CK...
  • Page 35: Start-Up

    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...
  • Page 36: Programming The Electronic High/Low Thermostat

    Name Set Button Up Arrow button Down Arrow button 2-40 HP Portable Chillers Description The Set button is used to enter the programming mode for the thermostat. Each press of the Down Arrow key decrements or reduces values or settings on the display Each press of the Up Arrow key increments or advances the values or settings on the display.
  • Page 37 C1 for cooling or H1 for Heating. Use the Up Arrow and Down Arrow keys to toggle between C1 and H1. The setting should be C1. 2-40 HP Portable Chillers Chapter 4: Operation 37 of 78...
  • Page 38: Chapter 5: Maintenance

    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...
  • Page 39: Maintaining The Condenser

    A0502600) through the water side of the condenser. Follow the directions on the container. Shell & 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.
  • Page 40: Preventative Maintenance Service

    • 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...
  • Page 41: Chapter 6: Troubleshooting

    Chapter 6: Troubleshooting Problem Unit does not run. Pump runs; compressor does not. Pump runs, compressor cycles at short intervals. 2-40 HP Portable Chillers Possible cause No power. Wrong voltage supplied to unit. Defective on/off switch. Control circuit fuse blown.
  • Page 42 Pump pressure low (refer to curves for normal pressure for various pumps). Pump pressure is too high. Unit runs continuously, but not enough cooling power. 2-40 HP Portable Chillers Possible cause Water/glycol mixture inadequate for process. Defective or improperly set High/Low thermostat.
  • Page 43: Chapter 7: Appendix

    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...
  • Page 44: Technical Assistance

    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...
  • Page 45: Drawings And Specifications

    Based on 50ºF (10ºC) chilled water supply temperature and 95ºF (35ºC) 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 on 2.4 gpm per ton (9.1 lpm per 3.517 kW), nominal 1 pump.
  • Page 46: Hp And 7.5 Hp Air-Cooled Portable Chillers

    Based on 2.4 gpm per ton (9.1 lpm 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.
  • Page 47: Hp And 15 Hp Air-Cooled Portable Chillers

    Based on 2.4 gpm per ton (9.1 lpm 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.
  • Page 48: Hp, 25 Hp, And 30 Hp Air-Cooled Portable Chillers

    Based on 50ºF (10ºC) chilled water supply temperature and 95ºF (35ºC) 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 lpm per 3.517 kW), nominal 1 pump.
  • Page 49: Hp And 3.5 Hp Water-Cooled Portable Chillers

    Based on 50ºF (10ºC) chilled water supply temperature and 85ºF (29ºC) 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 lpm per 3.517 kW), nominal 1 pump.
  • Page 50: Hp And 7.5 Hp Water-Cooled Portable Chillers

    Based on 50ºF (10ºC) chilled water supply temperature and 85ºF (29ºC) 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 on 2.4 gpm per ton (9.1 lpm per 3.517 kW), nominal 1 pump.
  • Page 51: Hp And 15 Hp Water-Cooled Portable Chillers

    Based on 50ºF (10ºC) chilled water supply temperature and 85ºF (29ºC) 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 on 2.4 gpm per ton (9.1 lpm per 3.517 kW), nominal 1 pump.
  • Page 52: Hp, 25 Hp, And 30 Hp Water-Cooled Portable Chillers

    Based on 50ºF (10ºC) chilled water supply temperature and 85ºF (29ºC) 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 on 2.4 gpm per ton (9.1 lpm per 3.517 kW), nominal 1 pump.
  • Page 53: Hp And 40 Hp Water-Cooled Portable Chillers

    Based on 50ºF (10ºC) chilled water supply temperature and 85ºF (29ºC) 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 on 2.4 gpm per ton (9.1 lpm per 3.517 kW), nominal 1 pump.
  • Page 54: Hp And 7.5 Hp Remote Air-Cooled Portable Chillers

    Based on 50ºF (10ºC) chilled water supply temperature and 95ºF (35ºC) 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 lpm per 3.517 kW), nominal 1 pump.
  • Page 55: Hp And 15 Hp Remote Air-Cooled Portable Chillers

    Based on 50ºF (10ºC) chilled water supply temperature and 95ºF (35ºC) 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 lpm per 3.517 kW), nominal 1 pump.
  • Page 56: Hp Through 40 Hp Remote Air-Cooled Portable Chillers

    Based on 50ºF (10ºC) chilled water supply temperature and 95ºF (35ºC) 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 lpm per 3.517 kW), nominal 1 pump.
  • Page 57: Remote Condenser Assembly Models

    30 1 1/2 hp 3 ø 12.9 ø 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 ¾ hp (0.56 kW) single phase variable speed. Multiply 460V amperages by 2.0 for 208-230V amperages.
  • Page 60: Water Pressure Drop Tables

    • Pressure: Obtain a corresponding pressure reading 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. • For two-pump (Process/Recirc) chillers, do not subtract pressure drop from table above for process pump.
  • Page 61: Flow And Pressure Considerations

    Flow and Pressure Considerations Model Design flow -A, 2 hp 17.5 -A, 3.5 hp 29.9 -A, -R, 5 hp 11.6 43.8 -A, -R, 7.5 hp 15.7 59.6 -A, -R, 10 hp 23.8 90.1 -A, -R, 15 hp 34.9 132.1 -A, -R, 20 hp 46.5...
  • Page 62: Remote Air-Cooled Chiller Configurations

    Remote Air-Cooled Chiller Configurations Configuration A: *Liquid line riser should not exceed 15 feet from base of air-cooled condenser. Configuration B: Configuration C: 2-40 HP Portable Chillers Chapter 7: Appendix 62 of 78...
  • Page 63: Typical Ductwork For Air-Cooled Chillers

    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 •...
  • Page 64: Piping Diagrams

    Piping Diagrams Central and Gravity Return Piping with Standpipe Diagram 2-40 HP Portable Chillers Chapter 7: Appendix 64 of 78...
  • 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 78...
  • 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 78...
  • 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 78...
  • 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 78...
  • 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 78...
  • Page 70: Electrical Schematics

    Typical Electrical Subpanel Time-delay Relays Relays Optional Fan Motor Speed Control High/Low T’stat Compressor, Pump, and Fan Motor Fuses Compressor, Pump, and Fan Motor Starters 2-40 HP Portable Chillers Fuses Control Transformer Chapter 7: Appendix Disconnect Switch 70 of 78...
  • Page 71: Typical Electrical Schematic, 2 Hp And 3 1/2 Hp Models

    Typical Electrical Schematic, 2 hp and 3 1/2 hp Models 2-40 HP Portable Chillers Chapter 7: Appendix 71 of 78...
  • Page 72: Typical Power Wiring Schematic, 5 Hp Through 40 Hp Models

    Typical Power Wiring Schematic, 5 hp through 40 hp Models 1DISC GROUNDING BAR PANEL GROUND OVERCURRENT PROTECTION BY OTHERS PROTECTED PER N.E.C. LOW AMBIENT AIR COOLED STANDARD AND HIGH PRESSURE AIR COOLED LOCATED OUTSIDE OF ENCLOSURE COMPONENT WIRING BY OTHERS...
  • Page 73: Typical Wiring Schematic, 5 Hp Through 15 Hp Models With Pump

    Typical Wiring Schematic, 5 hp through 15 hp Models with Pump 2-40 HP Portable Chillers Chapter 7: Appendix 73 of 78...
  • Page 74: Typical Wiring Schematic, 5 Hp Through 15 Hp Models Without Pump

    Typical Wiring Schematic, 5 hp through 15 hp Models without Pump DWG: A0554931 2-40 HP Portable Chillers Chapter 7: Appendix 74 of 78...
  • Page 75: Typical Wiring Schematic, 20 Hp Through 30 Hp Models With Pump

    Typical Wiring Schematic, 20 hp through 30 hp Models with Pump DWG: A0562343 2-40 HP Portable Chillers Chapter 7: Appendix 75 of 78...
  • Page 76: Typical Wiring Schematic, 20 Hp Through 30 Hp Models Without Pump

    Typical Wiring Schematic, 20 hp through 30 hp Models without Pump DWG: A0562435 2-40 HP Portable Chillers Chapter 7: Appendix 76 of 78...
  • Page 77: Typical Wiring Schematic, 35 Hp And 40 Hp Models With Pump

    Typical Wiring Schematic, 35 hp and 40 hp Models with Pump DWG: A0562344 2-40 HP Portable Chillers Chapter 7: Appendix 77 of 78...
  • Page 78: Typical Wiring Schematic, 35 Hp And 40 Hp Models Without Pump

    Typical Wiring Schematic, 35 hp and 40 hp Models without Pump DWG: A0562434 2-40 HP Portable Chillers Chapter 7: Appendix 78 of 78...