Page 2 - Shipping Information; Unpacking and Inspection; Do not; If the Shipment is Not Complete; contact the shipping department immediately; Hold the items until you receive shipping instructions
2-40 HP Portable Chillers ii Shipping Information Unpacking and Inspection You should inspect your equipment for possible shipping damage. Thoroughly check theequipment for any damage that might have occurred in transit, such as broken or loose wiringand components, loose hardware and mounting screw...
Page 3 - Table of Contents
2-40 HP Portable Chillers iii Table of Contents CHAPTER 1: SAFETY ................................................................. 6 1-1 How to Use This Manual ............................................................................................. 6 Safety Symbols Used in this Manual ...........
Page 5 - -40 HP Portable Chillers
2-40 HP Portable Chillers v Flow and Pressure Considerations ..................................................................... 61Recirculation Pump Specifications ...................................................................... 61 7-5 Remote Air-Cooled Chiller Configurations .................
Page 6 - -1 How to Use This Manual; Safety Symbols Used in this Manual
2-40 HP Portable Chillers Chapter 1: Safety 6 of 78 Chapter 1: Safety 1-1 How to Use This Manual Use this manual as a guide and reference for installing, operating, and maintaining yourequipment. The purpose is to assist you in applying efficient, proven techniques that enhanceequipment productivity...
Page 7 - -2 Warnings and Precautions
2-40 HP Portable Chillers Chapter 1: Safety 7 of 78 1-2 Warnings and Precautions Our equipment is designed to provide safe and reliable operation when installed and operatedwithin design specifications, following national and local safety codes. To avoid possible personal injury or equipment damage ...
Page 8 - Chapter 2: Functional Description; -1 Models Covered in This Manual
2-40 HP Portable Chillers Chapter 2: Functional Description 8 of 78 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. ...
Page 9 - Description; Chilled Water Circuit
2-40 HP Portable Chillers Chapter 2: Functional Description 9 of 78 2-2 General Description Our portable chillers are reliable, accurate, and easy to use process cooling units. They areavailable in air-, water-, and remote air-cooled designs in a range of sizes from 2 to 40 tons.All are self-contain...
Page 10 - Features; Mechanical Features; Other Mechanical Features
2-40 HP Portable Chillers Chapter 2: Functional Description 10 of 78 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 (26.20and 29.83 kW) m...
Page 12 - -4 Safety Devices and Interlocks; High/Low Thermostat Control
2-40 HP Portable Chillers Chapter 2: Functional Description 12 of 78 • Three year limited controller warranty 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. Stageone of the thermostat shuts down t...
Page 14 - Communications Options.
2-40 HP Portable Chillers Chapter 2: Functional Description 14 of 78 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 val...
Page 17 - Chapter 3: Installation; Pry the crating away from the skid.; Connections
2-40 HP Portable Chillers Chapter 3: Installation 17 of 78 Chapter 3: Installation 3-1 Uncrating 2 hp to 5 hp models are shipped mounted on a skid, enclosed in a plastic wrapper, andcontained in a cardboard box. 7.5 to 40 hp models are shipped mounted on a skid, enclosed ina plastic wrapper, and ope...
Page 18 - -3 Process Water Connections
2-40 HP Portable Chillers Chapter 3: Installation 18 of 78 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, la...
Page 19 - Considerations; Water-Cooled Chiller Condensers; Condenser Water Out.; Air-Cooled Chiller Condensers; Condensing Air Temperature.
2-40 HP Portable Chillers Chapter 3: Installation 19 of 78 3-7 Condenser Considerations Water-Cooled Chiller Condensers Water-cooled portable chillers can use city water or tower water as a cooling medium. Makesure that all external piping and connections supplying and discharging water to and from ...
Page 20 - Interconnecting Refrigerant Piping.; The chiller and condenser refrigerant lines are
2-40 HP Portable Chillers Chapter 3: Installation 20 of 78 Remote Air-Cooled Chiller Condensers Remote air-cooled portable chillers are shipped with nitrogen holding charge and a fullcharge of oil (excluding the amount needed for field piping). The remote air condenser isshipped with a dry air charg...
Page 21 - System Configuration.; The system can be configured in any of the arrangements shown on; Sizing Refrigerant Lines.; Discharge Line Sizing.
2-40 HP Portable Chillers Chapter 3: Installation 21 of 78 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 thecondenser affects pipe size, refrigerant charge, oil return, and oil ch...
Page 22 - Figure 2: Equivalent Length in Feet for Valves and Fittings
2-40 HP Portable Chillers Chapter 3: Installation 22 of 78 Figure 2: Equivalent Length in Feet for Valves and Fittings Line Size Inches OD Globe Valve Equivalent Ft Angle Valve Equivalent Ft Short Radius Elbow Equivalent Ft Long Radius Elbow Equivalent Ft 1/2” 43 15 1.4 0.9 5/8” 55 18 1.6 1.0 7/8” 6...
Page 23 - Refrigerant Charge Determination.; The approximate amount of refrigerant charge required; Figure 5: Refrigerant Charge Determination; Oil Charge Determination.; The remote air-cooled portable chillers are factory charged with
2-40 HP Portable Chillers Chapter 3: Installation 23 of 78 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 thechiller. Referring to Figure 5, determine the amount of charge...
Page 24 - -8 Checking Motor Direction; Do not switch leads at the motors, motor starters, or contactors.
2-40 HP Portable Chillers Chapter 3: Installation 24 of 78 3-8 Checking Motor Direction All of our portable chillers have their motor rotations properly phased at the factory. Ifcompressors, pumps, or fans are running in reverse rotation, disconnect and lock out thepower source and reverse any two p...
Page 25 - Reservoir; The following glycol products are available:; Part Number
2-40 HP Portable Chillers Chapter 3: Installation 25 of 78 3-9 Water Reservoir All portable chillers shipped during the fall, winter, or spring, or those units that are shippedfrom stock are flushed at the factory with a water/ethylene glycol solution to prevent pipingcomponents prone to retaining w...
Page 26 - Figure 6: Ethylene Glycol and Propylene Glycol Curves
2-40 HP Portable Chillers Chapter 3: Installation 26 of 78 Figure 6: Ethylene Glycol and Propylene Glycol Curves Pe r ce n t G lyc o l Cu rves fo r F ree z e P ro tec t ion -60.0 -50.0 -40.0 -30.0 -20.0 -10.0 0.0 10.0 20.0 30.0 40.0 0.0 10.0 20.0 30.0 40.0 50.0 60.0 % Gl ycol b y V ol um e Eth yl en...
Page 29 - Chapter 4: Operation; Microprocessor Controllers; E5CK Controller; PV
2-40 HP Portable Chillers Chapter 4: Operation 29 of 78 Chapter 4: Operation 4-1 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...
Page 30 - AT; SP
2-40 HP Portable Chillers Chapter 4: Operation 30 of 78 Indicator Name Description SUB1 SUB 1 LED The orange SUB1 LED lights when the processtemperature is two degrees or more below the “ToProcess” setpoint. The compressor then shutsdown by means of a latching circuit, and it doesnot run again until...
Page 31 - Figure 7: Typical Portable Chiller Microprocessor Controllers; P V; S V; O M R O N; H T
2-40 HP Portable Chillers Chapter 4: Operation 31 of 78 Figure 7: Typical Portable Chiller Microprocessor Controllers P V S V O U T 1 O U T 2 M ANU S T O P R M T AT SUB1 AT E5CK O M R O N S P T MADE IN U.S.A. 2000 H T CL AL R E M ° F ° C %
Page 32 - Indicator; Pump On Light
2-40 HP Portable Chillers Chapter 4: Operation 32 of 78 Graphic Panel (See Figure 8 on Page 32. ) Indicator Name Description Compressor OnLight The Compressor On light turns on whenever thecompressor is operating. Low TemperatureLight The Low Temperature light comes on if the processwater/glycol tem...
Page 34 - Figure 8: Typical Graphic Panels
2-40 HP Portable Chillers Chapter 4: Operation 34 of 78 Figure 8: Typical Graphic Panels (With E5CK Controller) (With Sterlco 2000 Controller) O N O F F CONTROL P O W E R A0554705 SILENCE ALARM CO M PR E SSO R O N HOT GAS BY-PASS P UMP ON P U M P OVERLOAD LOW WATER FLOW/PRESSURE L O W TEM PERATURE H...
Page 35 - -3 Setting the Process Water Temperatures; Communications
2-40 HP Portable Chillers Chapter 4: Operation 35 of 78 4-2 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 UpArrow button or the Down Arrow button located on the face of the controller. 3. Adjust the High/Low ...
Page 36 - -6 Programming the Electronic High/Low Thermostat; Thermostat Buttons; Set Button
2-40 HP Portable Chillers Chapter 4: Operation 36 of 78 4-6 Programming the Electronic High/Low Thermostat The thermostat control is located in the chiller enclosure. The control has three control keysand a one-line, four-character LCD display. The thermostat control has a lockout slide switch to pr...
Page 37 - Select Fahrenheit or Celsius
2-40 HP Portable Chillers Chapter 4: Operation 37 of 78 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 modeUse the Up Arrow and Down Arrow keys to toggle between Fahrenheit an...
Page 38 - Chapter 5: Maintenance; Cleaning; Turn the chiller off.
2-40 HP Portable Chillers Chapter 5: Maintenance 38 of 78 Chapter 5: Maintenance 5-1 Lubrication Grease all blower bearings, fan and blower motors, and pump motors that do not havepermanently sealed bearings. Remove the grease relief plug (motors only) before addinggrease, add grease until a small a...
Page 39 - -3 Maintaining the Condenser; Water-Cooled Chillers; -4 Maintaining the Evaporator
2-40 HP Portable Chillers Chapter 5: Maintenance 39 of 78 5-3 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 ordamaging...
Page 40 - -6 Preventative Maintenance Service
2-40 HP Portable Chillers Chapter 5: Maintenance 40 of 78 5-6 Preventative Maintenance Service Follow a systematic preventive maintenance program to help avoid costly down time. Callthe Service Department to arrange a schedule of inspections. This service can be tailored tofit your maintenance requi...
Page 41 - Chapter 6: Troubleshooting
2-40 HP Portable Chillers Chapter 6: Troubleshooting 41 of 78 Chapter 6: Troubleshooting Problem Possible cause Solution No power. Check main disconnect, fuses, wiring,and power lead to unit. Wrong voltage supplied to unit. Voltage must be within plus or minus10% of nameplate rating. Defective on/of...
Page 44 - Assistance; Parts Department
2-40 HP Portable Chillers Chapter 7: Appendix 44 of 78 7-2 Technical Assistance Parts Department Call toll-free 7am–5pm CST [800] 423-3183 or call [414] 354-0970, Fax [414] 354-6421The ACS Customer Service Group will provide your company with genuine OEM quality partsmanufactured to engineering desi...
Page 45 - -3 Drawings and Specifications; hp and 3 1/2 hp Air-Cooled Portable Chillers
2-40 HP Portable Chillers Chapter 7: Appendix 45 of 78 7-3 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. Fo...
Page 58 - Pump Curves, Flow, and Pressure Considerations; 0 Hertz Pump Curves
2-40 HP Portable Chillers Chapter 7: Appendix 58 of 78 7-4 Pump Curves, Flow, and Pressure Considerations 60 Hertz Pump Curves DWG. No. A 0554823
Page 60 - Water Pressure Drop Tables; Calculating Chiller Nominal Flow and Pressure to Process
2-40 HP Portable Chillers Chapter 7: Appendix 60 of 78 Water Pressure Drop Tables Note: A recirculation pump is required for flows greater than themaximum or less than the minimum indicated. Note: Process flow less than or greater than the flow rates shown belowrequires a recirculation pump. Pressur...
Page 62 - -5 Remote Air-Cooled Chiller Configurations
2-40 HP Portable Chillers Chapter 7: Appendix 62 of 78 7-5 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:
Page 63 - -6 Typical Ductwork for Air-Cooled Chillers
2-40 HP Portable Chillers Chapter 7: Appendix 63 of 78 7-6 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 hightemperature conditions w...
Page 64 - Diagrams; Central and Gravity Return Piping with Standpipe Diagram
2-40 HP Portable Chillers Chapter 7: Appendix 64 of 78 7-7 Piping Diagrams Central and Gravity Return Piping with Standpipe Diagram
Page 70 - Schematics; Typical Electrical Subpanel
2-40 HP Portable Chillers Chapter 7: Appendix 70 of 78 7-8 Electrical Schematics Typical Electrical Subpanel Time-delay Relays Relays Optional Fan Motor Speed Control Control Transformer Fuses High/Low T’stat Disconnect Switch Compressor, Pump, and Fan Motor Fuses Compressor, Pump, and Fan Motor Sta...
