Page 2 - Shipping Information; Unpacking and Inspection; Do not; If the Shipment is Not Complete; contact the parts and service department; Hold the
2-40 HP Portable Chillers ii 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 scr...
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...................................................................... 61 Recirculation 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 70 Chapter 1: Safety 1-1 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 productivi...
Page 7 - -2 Warnings and Precautions
2-40 HP Portable Chillers Chapter 1: Safety 7 of 70 1-2 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...
Page 8 - Chapter 2: Functional Description; -1 Models Covered in This Manual
2-40 HP Portable Chillers Chapter 2: Functional Description 8 of 70 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 70 2-2 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-conta...
Page 10 - Features; Mechanical Features; Other Mechanical Features
2-40 HP Portable Chillers Chapter 2: Functional Description 10 of 70 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 (26.20 and 29.83 kW) ...
Page 12 - Devices and Interlocks; High/Low Thermostat Control
2-40 HP Portable Chillers Chapter 2: Functional Description 12 of 70 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. Stage one of the thermostat shuts down the compressor if the chilled process wat...
Page 14 - Communications Options.
2-40 HP Portable Chillers Chapter 2: Functional Description 14 of 70 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 70 Chapter 3: Installation 3-1 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 o...
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 70 3-7 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...
Page 20 - Interconnecting Refrigerant Piping.; The chiller and condenser refrigerant lines are
2-40 HP Portable Chillers Chapter 3: Installation 20 of 70 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 nitroge...
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 70 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 c...
Page 22 - Figure 2: Equivalent Length in Feet for Valves and Fittings
2-40 HP Portable Chillers Chapter 3: Installation 22 of 70 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 70 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 charg...
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 70 3-8 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...
Page 25 - Reservoir; The following glycol products are available:; Part Number
2-40 HP Portable Chillers Chapter 3: Installation 25 of 70 3-9 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...
Page 26 - Figure 6: Ethylene Glycol and Propylene Glycol Curves
2-40 HP Portable Chillers Chapter 3: Installation 26 of 70 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 r o 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 y col b y V ol um e Eth y l...
Page 29 - Chapter 4: Operation; Microprocessor Controllers; E5CK Controller
2-40 HP Portable Chillers Chapter 4: Operation 29 of 70 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 mountin...
Page 30 - AT; SP
2-40 HP Portable Chillers Chapter 4: Operation 30 of 70 Indicator Name Description SUB1 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 down by means of a latching circuit, and it does not run again...
Page 31 - Figure 7: Typical Portable Chiller Microprocessor Controllers; P V; S V
2-40 HP Portable Chillers Chapter 4: Operation 31 of 70 Figure 7: Typical Portable Chiller Microprocessor Controllers P V S V O U T 1 O U T 2 M A N U S T O P R M T A T S UB 1 AT E 5 CK O M R O N
Page 32 - Figure 8; Pump On Light
2-40 HP Portable Chillers Chapter 4: Operation 32 of 70 Graphic Panel (See Figure 8 ) Indicator Name Description Compressor On Light The Compressor On light turns on whenever the compressor is operating. Low Temperature Light The Low Temperature light comes on if the process water/glycol temperature...
Page 33 - Indicator
2-40 HP Portable Chillers Chapter 4: Operation 33 of 70 Indicator Name Description Low Water Flow/Pressure Light 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...
Page 34 - Figure 8: Typical Graphic Panels
2-40 HP Portable Chillers Chapter 4: Operation 34 of 70 Figure 8: Typical Graphic Panels (With E5CK Controller) (Eurotherm 3216 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 I ...
Page 35 - -3 Setting the Process Water Temperatures; Chiller Controller; Press the UP arrow once to display “on”.; Communications
2-40 HP Portable Chillers Chapter 4: Operation 35 of 70 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 Up Arrow 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 70 4-6 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 p...
Page 37 - Select Fahrenheit or Celsius
2-40 HP Portable Chillers Chapter 4: Operation 37 of 70 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 b...
Page 38 - Chapter 5: Maintenance; Cleaning; Turn the chiller off.
2-40 HP Portable Chillers Chapter 5: Maintenance 38 of 70 Chapter 5: Maintenance 5-1 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...
Page 39 - -3 Maintaining the Condenser; Water-Cooled Chillers; -4 Maintaining the Evaporator
2-40 HP Portable Chillers Chapter 5: Maintenance 39 of 70 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 or damagin...
Page 40 - -6 Preventative Maintenance Service
2-40 HP Portable Chillers Chapter 5: Maintenance 40 of 70 5-6 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 req...
Page 41 - Chapter 6: Troubleshooting
2-40 HP Portable Chillers Chapter 6: Troubleshooting 41 of 70 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 minus 10% of nameplate rating. Defective on/...
Page 43 - Chapter 7: Appendix; -1 Returned Material Policy; Credit Returns
2-40 HP Portable Chillers Chapter 7: Appendix 43 of 70 Chapter 7: Appendix 7-1 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 retu...
Page 44 - Assistance; Parts Department
2-40 HP Portable Chillers Chapter 7: Appendix 44 of 70 7-2 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 de...
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 70 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. F...
Page 60 - Evaporator Water Pressure Drop Tables; Calculating Chiller Nominal Flow and Pressure to Process
2-40 HP Portable Chillers Chapter 7: Appendix 60 of 70 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 ...
Page 62 - -5 Remote Air-Cooled Chiller Configurations
2-40 HP Portable Chillers Chapter 7: Appendix 62 of 70 7-5 Remote Air-Cooled Chiller Configurations
Page 63 - -6 Typical Ductwork for Air-Cooled Chillers
2-40 HP Portable Chillers Chapter 7: Appendix 63 of 70 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 high temperature conditions...
Page 64 - Diagrams; Central and Gravity Return Piping with Standpipe Diagram
2-40 HP Portable Chillers Chapter 7: Appendix 64 of 70 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 70 7-8 Electrical Schematics Typical Electrical Subpanel Please refer to your owner’s information packet for more details regarding your specific unit. DWG: A0562434
